Factory Workshop Manual
Make
Ford
Model
Explorer Awd
Engine and year
V6-4.0L VIN K Flex Fuel (2003)
Please navigate through the PDF using the options
provided by OnlyManuals.com on the sidebar.
This manual was submitted by
Anonymous
Date
1st January 2018
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010
P0010 - P0014: Testing and Inspection P0010
For diagnosis of code P0010 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 10
P0010 - P0014: Testing and Inspection P0011
For diagnosis of code P0011 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 12
P0010 - P0014: Testing and Inspection P0012
For diagnosis of code P0012 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014,
( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 13
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020
P0020 - P0024: Testing and Inspection P0020
For diagnosis of code P0020 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 19
P0020 - P0024: Testing and Inspection P0021
For diagnosis of code P0021 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 21
P0020 - P0024: Testing and Inspection P0022
For diagnosis of code P0022 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024,
( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044,
( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040
P0040 - P0044: Testing and Inspection P0040
For diagnosis of code P0040 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044,
( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044,
( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > Page 28
P0040 - P0044: Testing and Inspection P0041
For diagnosis of code P0041 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044,
( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054,
( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053
P0050 - P0054: Testing and Inspection P0053
For diagnosis of code P0053 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054,
( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054,
( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > Page 35
P0050 - P0054: Testing and Inspection P0054
For diagnosis of code P0054 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054,
( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0055 - P0059,
( P0056 P0057 P0058 0055 0056 0057 0058 0059 ) > System Information > System Diagnosis
P0055 - P0059: Testing and Inspection
For diagnosis of code P0059 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0060 - P0064,
( P0061 P0062 P0063 0060 0061 0062 0063 0064 ) > System Information > System Diagnosis
P0060 - P0064: Testing and Inspection
For diagnosis of code P0060 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0065 - P0069,
( P0066 P0067 P0068 0065 0066 0067 0068 0069 ) > System Information > System Diagnosis
P0065 - P0069: Testing and Inspection
For diagnosis of code P0068 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 51
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 52
P0100 - P0104: Testing and Inspection P0103
For diagnosis of code P0103 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 53
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 58
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 59
P0105 - P0109: Testing and Inspection P0107
For diagnosis of code P0107 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 60
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 61
P0105 - P0109: Testing and Inspection P0108
For diagnosis of code P0108 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 62
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 63
P0105 - P0109: Testing and Inspection P0109
For diagnosis of code P0109 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 64
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 69
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 70
P0110 - P0114: Testing and Inspection P0113
For diagnosis of code P0113 refer to chart
Bxxx - P0113
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 71
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 76
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 77
P0115 - P0119: Testing and Inspection P0117
For diagnosis of code P0117 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 78
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 79
P0115 - P0119: Testing and Inspection P0118
For diagnosis of code P0118 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 80
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 85
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 86
P0120 - P0124: Testing and Inspection P0122
For diagnosis of code P0122 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 87
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 88
P0120 - P0124: Testing and Inspection P0123
For diagnosis of code P0123 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 89
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 94
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 95
P0125 - P0129: Testing and Inspection P0128
For diagnosis of code P0128 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 96
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 101
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 102
P0130 - P0134: Testing and Inspection P0132
For diagnosis of code P0132 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 103
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 104
P0130 - P0134: Testing and Inspection P0133
For diagnosis of code P0133 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 105
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 110
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 111
P0135 - P0139: Testing and Inspection P0136
For diagnosis of code P0136 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 112
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 113
P0135 - P0139: Testing and Inspection P0138
For diagnosis of code P0138 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 114
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 118
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 122
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 127
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 128
P0150 - P0154: Testing and Inspection P0152
For diagnosis of code P0152 refer to chart
P0116 - P0152
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 129
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 130
P0150 - P0154: Testing and Inspection P0153
For diagnosis of code P0153 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 131
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 136
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 137
P0155 - P0159: Testing and Inspection P0156
For diagnosis of code P0156 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 138
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 139
P0155 - P0159: Testing and Inspection P0158
For diagnosis of code P0158 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 140
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 144
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 149
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 150
P0170 - P0174: Testing and Inspection P0172
For diagnosis of code P0172 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 151
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 152
P0170 - P0174: Testing and Inspection P0174
For diagnosis of code P0174 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 153
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P0179: Testing and Inspection
For diagnosis of code P0175 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 157
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 162
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 163
P0180 - P0184: Testing and Inspection P0181
For diagnosis of code P0181 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 164
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 165
P0180 - P0184: Testing and Inspection P0182
For diagnosis of code P0182 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 166
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 167
P0180 - P0184: Testing and Inspection P0183
For diagnosis of code P0183 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 168
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 173
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 174
P0190 - P0194: Testing and Inspection P0191
For diagnosis of code P0191 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 175
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 176
P0190 - P0194: Testing and Inspection P0192
For diagnosis of code P0192 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 177
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 178
P0190 - P0194: Testing and Inspection P0193
For diagnosis of code P0193 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 179
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196
P0195 - P0199: Testing and Inspection P0196
For diagnosis of code P0196 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 184
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 185
P0195 - P0199: Testing and Inspection P0197
For diagnosis of code P0197 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 186
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 187
P0195 - P0199: Testing and Inspection P0198
For diagnosis of code P0198 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199,
( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 188
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 194
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 195
P0200 - P0204: Testing and Inspection P0202
For diagnosis of code P0202 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 196
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 197
P0200 - P0204: Testing and Inspection P0203
For diagnosis of code P0203 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 198
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 199
P0200 - P0204: Testing and Inspection P0204
For diagnosis of code P0204 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 200
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 205
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 206
P0205 - P0209: Testing and Inspection P0206
For diagnosis of code P0206 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 207
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 208
P0205 - P0209: Testing and Inspection P0207
For diagnosis of code P0207 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 209
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 210
P0205 - P0209: Testing and Inspection P0208
For diagnosis of code P0208 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 211
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 212
P0205 - P0209: Testing and Inspection P0209
For diagnosis of code P0209 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 213
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 218
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 219
P0210 - P0214: Testing and Inspection P0211
For diagnosis of code P0211 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 220
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 221
P0210 - P0214: Testing and Inspection P0212
For diagnosis of code P0212 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 222
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 P0219 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 226
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221
P0220 - P0224: Testing and Inspection P0221
For diagnosis of code P0221 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 231
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 232
P0220 - P0224: Testing and Inspection P0222
For diagnosis of code P0222 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 233
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 234
P0220 - P0224: Testing and Inspection P0223
For diagnosis of code P0223 refer to chart
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224,
( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 235
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0153 - P0230
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 240
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 241
P0230 - P0234: Testing and Inspection P0231
For diagnosis of code P0231 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 242
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 243
P0230 - P0234: Testing and Inspection P0232
For diagnosis of code P0232 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 244
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0297
P0295 - P0299: Testing and Inspection P0297
For diagnosis of code P0297 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0297 > Page 249
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0297 > Page 250
P0295 - P0299: Testing and Inspection P0298
For diagnosis of code P0298 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0297 > Page 251
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 257
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 258
P0300 - P0304: Testing and Inspection P0301
For diagnosis of code P0301 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 259
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 260
P0300 - P0304: Testing and Inspection P0302
For diagnosis of code P0302 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 261
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 262
P0300 - P0304: Testing and Inspection P0303
For diagnosis of code P0303 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 263
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 264
P0300 - P0304: Testing and Inspection P0304
For diagnosis of code P0304 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 265
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 270
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 271
P0305 - P0309: Testing and Inspection P0306
For diagnosis of code P0306 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 272
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 273
P0305 - P0309: Testing and Inspection P0307
For diagnosis of code P0307 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 274
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 275
P0305 - P0309: Testing and Inspection P0308
For diagnosis of code P0308 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 276
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 277
P0305 - P0309: Testing and Inspection P0309
For diagnosis of code P0309 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 278
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 282
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319,
( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315
P0315 - P0319: Testing and Inspection P0315
For diagnosis of code P0315 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319,
( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 287
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319,
( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 288
P0315 - P0319: Testing and Inspection P0316
For diagnosis of code P0316 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319,
( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 289
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 293
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 298
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 299
P0325 - P0329: Testing and Inspection P0326
For diagnosis of code P0326 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 300
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 305
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 306
P0330 - P0334: Testing and Inspection P0331
For diagnosis of code P0331 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 307
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 311
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349,
( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis
P0345 - P0349: Testing and Inspection
For diagnosis of code P0345 refer to chart
P0231 - P0400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349,
( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis > Page 315
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 320
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 321
P0350 - P0354: Testing and Inspection P0351
For diagnosis of code P0351 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 322
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 323
P0350 - P0354: Testing and Inspection P0352
For diagnosis of code P0352 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 324
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 325
P0350 - P0354: Testing and Inspection P0353
For diagnosis of code P0353 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 326
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 327
P0350 - P0354: Testing and Inspection P0354
For diagnosis of code P0354 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 328
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 333
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 334
P0355 - P0359: Testing and Inspection P0356
For diagnosis of code P0356 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 335
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 336
P0355 - P0359: Testing and Inspection P0357
For diagnosis of code P0357 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 337
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 338
P0355 - P0359: Testing and Inspection P0358
For diagnosis of code P0358 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 339
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 340
P0355 - P0359: Testing and Inspection P0359
For diagnosis of code P0359 refer to chart
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 341
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 345
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0231 - P0400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 351
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 352
P0400 - P0404: Testing and Inspection P0401
For diagnosis of code P0401 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 353
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 354
P0400 - P0404: Testing and Inspection P0402
For diagnosis of code P0402 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 355
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 356
P0400 - P0404: Testing and Inspection P0403
For diagnosis of code P0403 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 357
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409,
( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405
P0405 - P0409: Testing and Inspection P0405
For diagnosis of code P0405 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409,
( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 362
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409,
( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 363
P0405 - P0409: Testing and Inspection P0406
For diagnosis of code P0406 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409,
( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 364
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 369
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 370
P0410 - P0414: Testing and Inspection P0412
For diagnosis of code P0412 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 371
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0401 - P0482
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0401 - P0482
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
DTC Index P0442-P1450
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/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 382
P0440 - P0444: Testing and Inspection P0443
For diagnosis of code P0443 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 383
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0445 - P0449,
( P0446 P0447 P0448 0445 0446 0447 0448 0449 ) > System Information > System Diagnosis
P0445 - P0449: Testing and Inspection
For diagnosis of code P0446 refer to chart
P0401 - P0482
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 391
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 392
P0450 - P0454: Testing and Inspection P0452
For diagnosis of code P0452 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 393
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 394
P0450 - P0454: Testing and Inspection P0453
For diagnosis of code P0453 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 395
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
DTC Index P0442-P1450
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/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 400
P0455 - P0459: Testing and Inspection P0456
For diagnosis of code P0456 refer to chart
DTC Index P0442-P1450
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/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 401
P0455 - P0459: Testing and Inspection P0457
For diagnosis of P0457 refer to the system experiencing the problem.
Computers and Control Systems
P0401 - P0482
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 402
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Evaporative Emissions System
DTC Index P0442-P1450
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/Computers and Control Systems/Testing and Inspection
Instrument Cluster
DTC Index P0457
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 Instrument Cluster, follow this link: See: Instrument Panel, Gauges
and Warning Indicators/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 407
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 408
P0460 - P0464: Testing and Inspection P0461
For diagnosis of code P0461 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 409
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 410
P0460 - P0464: Testing and Inspection P0462
For diagnosis of code P0462 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 411
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 412
P0460 - P0464: Testing and Inspection P0463
For diagnosis of code P0463 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 413
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480
P0480 - P0484: Testing and Inspection P0480
For diagnosis of code P0480 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 418
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 419
P0480 - P0484: Testing and Inspection P0481
For diagnosis of code P0481 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 420
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 421
P0480 - P0484: Testing and Inspection P0482
For diagnosis of code P0482 refer to chart
P0401 - P0482
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484,
( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 422
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 code P0500 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 428
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 429
P0500 - P0504: Testing and Inspection P0501
For diagnosis of code P0501 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 430
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 431
P0500 - P0504: Testing and Inspection P0503
For diagnosis of code P0503 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 432
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0505 - P0509: Testing and Inspection P0505
For diagnosis of code P0505 refer to chart
P0500 - P071x
NOTE 16: Refer to the Diagnostic Trouble Code (DTC) Descriptions Chart for Descriptions,
Possible Causes and Diagnostic Aids for the DTC in question.
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 437
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 438
P0505 - P0509: Testing and Inspection P0506
For diagnosis of code P0506 refer to chart
P0500 - P071x
NOTE 16: Refer to the Diagnostic Trouble Code (DTC) Descriptions Chart for Descriptions,
Possible Causes and Diagnostic Aids for the DTC in question.
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 439
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 440
P0505 - P0509: Testing and Inspection P0507
For diagnosis of code P0507 refer to chart
P0500 - P071x
NOTE 16: Refer to the Diagnostic Trouble Code (DTC) Descriptions Chart for Descriptions,
Possible Causes and Diagnostic Aids for the DTC in question.
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 441
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514,
( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis
P0510 - P0514: Testing and Inspection
For diagnosis of code P0511 refer to chart
P0500 - 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
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514,
( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis > Page 445
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0525 - P0529,
( P0526 P0527 P0528 0525 0526 0527 0528 0529 ) > System Information > System Diagnosis
P0525 - P0529: Testing and Inspection
For diagnosis of code P0528 refer to chart
P0500 - 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
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0525 - P0529,
( P0526 P0527 P0528 0525 0526 0527 0528 0529 ) > System Information > System Diagnosis > Page 449
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534,
( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis
P0530 - P0534: Testing and Inspection
For diagnosis of code P0534 refer to chart
P0500 - 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
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534,
( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > Page 453
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539,
( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537
P0535 - P0539: Testing and Inspection P0537
For diagnosis of code P0537 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539,
( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 458
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539,
( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 459
P0535 - P0539: Testing and Inspection P0538
For diagnosis of code P0538 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539,
( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 460
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 465
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 466
P0550 - P0554: Testing and Inspection P0553
For diagnosis of code P0553 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 467
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 NOTE 7:
NOTE 7: The Vehicle ID (VID) Block must be reprogrammed. For instruction refer to the Flash VID
Block Procedure. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 473
P0600 - P0604: Testing and Inspection P0603
For diagnosis of code P0603 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 474
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0605 - P0609: Testing and Inspection P0605
For diagnosis of code P0605 refer to NOTE 10:
NOTE 10: Be sure to check for aftermarket performance products before replacing PCM. For
Electronic Throttle Control vehicles, P0606 may be set with other DTC's indicating a specific failure
in that system, and repairing those DTC's will fix the P0606. (Follow DTC chart for DTC's) For
diagnosing P0606 alone, an internal fault in the PCM is indicated, and the PCM should be
replaced. For replacement, refer to Flash Electrically Erasable Programmable Read Only Memory
(EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 479
P0605 - P0609: Testing and Inspection P0606
For diagnosis of code P0606 refer to NOTE 10:
NOTE 10: Be sure to check for aftermarket performance products before replacing PCM. For
Electronic Throttle Control vehicles, P0606 may be set with other DTC's indicating a specific failure
in that system, and repairing those DTC's will fix the P0606. (Follow DTC chart for DTC's) For
diagnosing P0606 alone, an internal fault in the PCM is indicated, and the PCM should be
replaced. For replacement, refer to Flash Electrically Erasable Programmable Read Only Memory
(EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624,
( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620
P0620 - P0624: Testing and Inspection P0620
For diagnosis of code P0620 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624,
( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 484
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624,
( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 485
P0620 - P0624: Testing and Inspection P0622
For diagnosis of code P0622 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624,
( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 486
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649,
( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis
P0645 - P0649: Testing and Inspection
For diagnosis of code P0645 refer to chart
P0500 - 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
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649,
( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis > Page 490
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664,
( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis
P0660 - P0664: Testing and Inspection
For diagnosis of code P0660 refer to chart
P0500 - 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
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664,
( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis > Page 494
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 system being tested:
Engine Control
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 500
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Cruise Control
DTC Index P0500 - P0703
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 Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 501
P0700 - P0704: Testing and Inspection P0704
For diagnosis of code P0574 refer to chart
P0500 - 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 502
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 507
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 508
P0705 - P0709: Testing and Inspection P0708
For diagnosis of code P0708 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 509
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0711
P0710 - P0714: Testing and Inspection P0711
For diagnosis of code P0711 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0711 > Page 514
P0710 - P0714: Testing and Inspection P0712
For diagnosis of code P0712 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0711 > Page 515
P0710 - P0714: Testing and Inspection P0713
For diagnosis of code P0713 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0715 - P0719: Testing and Inspection P0715
For diagnosis of code P0715 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 521
P0715 - P0719: Testing and Inspection P0717
For diagnosis of code P0717 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 522
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 523
P0715 - P0719: Testing and Inspection P0718
For diagnosis of code P0718 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 524
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 529
-
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 530
P0720 - P0724: Testing and Inspection Automatic Transmission
P0720
For diagnosis of code P0720 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 531
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
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 532
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
P0722 ( P 0722 )
For diagnosis of code P0722 refer to chart
If there is no link in the chart then:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 533
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 538
P0730 - P0734: Testing and Inspection P0732
For diagnosis of code P0732 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 539
P0730 - P0734: Testing and Inspection P0733
For diagnosis of code P0733 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 540
P0730 - P0734: Testing and Inspection P0734
For diagnosis of code P0734 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 541
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 545
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0740
P0740 - P0744: Testing and Inspection P0740
For diagnosis of code P0740 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0740 > Page 550
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0740 > Page 551
P0740 - P0744: Testing and Inspection P0743
For diagnosis of code P0743 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P0740 > Page 552
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0745 - P0749,
( P0746 P0747 P0748 0745 0746 0747 0748 0749 ) > System Information > System Diagnosis > P0745
P0745 - P0749: Testing and Inspection P0745
For diagnosis of code P0745 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0745 - P0749,
( P0746 P0747 P0748 0745 0746 0747 0748 0749 ) > System Information > System Diagnosis > P0745 > Page 557
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0745 - P0749,
( P0746 P0747 P0748 0745 0746 0747 0748 0749 ) > System Information > System Diagnosis > P0745 > Page 558
P0745 - P0749: Testing and Inspection P0748
For diagnosis of code P0748 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0745 - P0749,
( P0746 P0747 P0748 0745 0746 0747 0748 0749 ) > System Information > System Diagnosis > P0745 > Page 559
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0750 - P0754: Testing and Inspection P0750
For diagnosis of code P0750 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 565
P0750 - P0754: Testing and Inspection P0753
For diagnosis of code P0753 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0755 - P0759: Testing and Inspection P0755
For diagnosis of code P0755 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 570
P0755 - P0759: Testing and Inspection P0758
For diagnosis of code P0758 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 571
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0760 - P0764: Testing and Inspection P0760
For diagnosis of code P0760 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 576
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 577
P0760 - P0764: Testing and Inspection P0763
For diagnosis of code P0763 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 578
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P0765 - P0769: Testing and Inspection P0765
For diagnosis of code P0765 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 583
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 584
P0765 - P0769: Testing and Inspection P0768
For diagnosis of code P0768 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 585
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0775 - P0779,
( P0776 P0777 P0778 0775 0776 0777 0778 0779 ) > System Information > System Diagnosis > P0775
P0775 - P0779: Testing and Inspection P0775
For diagnosis of code P0775 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0775 - P0779,
( P0776 P0777 P0778 0775 0776 0777 0778 0779 ) > System Information > System Diagnosis > P0775 > Page 590
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0775 - P0779,
( P0776 P0777 P0778 0775 0776 0777 0778 0779 ) > System Information > System Diagnosis > P0775 > Page 591
P0775 - P0779: Testing and Inspection P0778
For diagnosis of code P0778 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0775 - P0779,
( P0776 P0777 P0778 0775 0776 0777 0778 0779 ) > System Information > System Diagnosis > P0775 > Page 592
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791
P0790 - P0794: Testing and Inspection P0791
For diagnosis of code P0791 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 597
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 598
P0790 - P0794: Testing and Inspection P0794
For diagnosis of code P0794 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794,
( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 599
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0795 - P0799,
( P0796 P0797 P0798 0795 0796 0797 0798 0799 ) > System Information > System Diagnosis > P0795
P0795 - P0799: Testing and Inspection P0795
For diagnosis of code P0795 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0795 - P0799,
( P0796 P0797 P0798 0795 0796 0797 0798 0799 ) > System Information > System Diagnosis > P0795 > Page 604
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0795 - P0799,
( P0796 P0797 P0798 0795 0796 0797 0798 0799 ) > System Information > System Diagnosis > P0795 > Page 605
P0795 - P0799: Testing and Inspection P0798
For diagnosis of code P0798 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0795 - P0799,
( P0796 P0797 P0798 0795 0796 0797 0798 0799 ) > System Information > System Diagnosis > P0795 > Page 606
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 611
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960
P0960 - P0964: Testing and Inspection P0960
For diagnosis of code P0960 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 617
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 618
P0960 - P0964: Testing and Inspection P0962
For diagnosis of code P0962 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 619
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 620
P0960 - P0964: Testing and Inspection P0963
For diagnosis of code P0963 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 621
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 622
P0960 - P0964: Testing and Inspection P0964
For diagnosis of code P0964 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0960 - P0964,
( P0961 P0962 P0963 0960 0961 0962 0963 0964 ) > System Information > System Diagnosis > P0960 > Page 623
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0965 - P0969,
( P0966 P0967 P0968 0965 0966 0967 0968 0969 ) > System Information > System Diagnosis > P0966
P0965 - P0969: Testing and Inspection P0966
For diagnosis of code P0966 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0965 - P0969,
( P0966 P0967 P0968 0965 0966 0967 0968 0969 ) > System Information > System Diagnosis > P0966 > Page 628
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0965 - P0969,
( P0966 P0967 P0968 0965 0966 0967 0968 0969 ) > System Information > System Diagnosis > P0966 > Page 629
P0965 - P0969: Testing and Inspection P0967
For diagnosis of code P0967 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0965 - P0969,
( P0966 P0967 P0968 0965 0966 0967 0968 0969 ) > System Information > System Diagnosis > P0966 > Page 630
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0965 - P0969,
( P0966 P0967 P0968 0965 0966 0967 0968 0969 ) > System Information > System Diagnosis > P0966 > Page 631
P0965 - P0969: Testing and Inspection P0968
For diagnosis of code P0968 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0965 - P0969,
( P0966 P0967 P0968 0965 0966 0967 0968 0969 ) > System Information > System Diagnosis > P0966 > Page 632
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0970 - P0974,
( P0971 P0972 P0973 0970 0971 0972 0973 0974 ) > System Information > System Diagnosis > P0970
P0970 - P0974: Testing and Inspection P0970
For diagnosis of code P0970 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0970 - P0974,
( P0971 P0972 P0973 0970 0971 0972 0973 0974 ) > System Information > System Diagnosis > P0970 > Page 637
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0970 - P0974,
( P0971 P0972 P0973 0970 0971 0972 0973 0974 ) > System Information > System Diagnosis > P0970 > Page 638
P0970 - P0974: Testing and Inspection P0971
For diagnosis of code P0971 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0970 - P0974,
( P0971 P0972 P0973 0970 0971 0972 0973 0974 ) > System Information > System Diagnosis > P0970 > Page 639
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
NOTE 1: DTC P1000 is ignored in KOEO an KOER Self-Test. Disregard DTC P1000 and continue
as directed.
If there is no link in the chart then:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 645
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 646
P1000 - P1004: Testing and Inspection P1001
For diagnosis of code P1001 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 647
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 653
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 654
P1100 - P1104: Testing and Inspection P1101
For diagnosis of code P1101 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 655
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1110 - P1114: Testing and Inspection
For diagnosis of code P1112 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 659
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1116
P1115 - P1119: Testing and Inspection P1116
For diagnosis of code P1116 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1116 > Page 664
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1116 > Page 665
P1115 - P1119: Testing and Inspection P1117
For diagnosis of code P1117 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1116 > Page 666
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 671
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 672
P1120 - P1124: Testing and Inspection P1121
For diagnosis of code P1121 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 673
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 674
P1120 - P1124: Testing and Inspection P1124
For diagnosis of code P1124 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 675
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 680
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 681
P1125 - P1129: Testing and Inspection P1127
For diagnosis of code P1127 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 682
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 683
P1125 - P1129: Testing and Inspection P1128
For diagnosis of code P1128 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 684
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 685
P1125 - P1129: Testing and Inspection P1129
For diagnosis of code P1129 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 686
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 691
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 692
P1130 - P1134: Testing and Inspection P1131
For diagnosis of code P1131 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 693
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 694
P1130 - P1134: Testing and Inspection P1132
For diagnosis of code P1132 refer to chart
P072x - P1132
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 695
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 700
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 701
P1135 - P1139: Testing and Inspection P1138
For diagnosis of code P1138 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 702
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 707
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 708
P1150 - P1154: Testing and Inspection P1151
For diagnosis of code P1151 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 709
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 710
P1150 - P1154: Testing and Inspection P1152
For diagnosis of code P1152 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 711
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 716
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 717
P1155 - P1159: Testing and Inspection P1158
For diagnosis of code P1158 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 718
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 723
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 724
P1165 - P1169: Testing and Inspection P1169
For diagnosis of code P1169 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 725
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 730
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 731
P1180 - P1184: Testing and Inspection P1181
For diagnosis of code P1181 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 732
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 733
P1180 - P1184: Testing and Inspection P1184
For diagnosis of code P1184 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 734
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 740
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 741
P1230 - P1234: Testing and Inspection P1233
For diagnosis of code P1233 refer to chart
P1137 - P1400
NOTE 6: Got to Information Bus for REM (Rear Electronics Module ) Self-test diagnostics. See:
Powertrain Management/Computers and Control Systems/Information Bus/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 742
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 743
P1230 - P1234: Testing and Inspection P1234
For diagnosis of code P1234 refer to chart
P1137 - P1400
NOTE 6: Got to Information Bus for REM (Rear Electronics Module ) Self-test diagnostics. See:
Powertrain Management/Computers and Control Systems/Information Bus/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 744
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 749
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 750
P1235 - P1239: Testing and Inspection P1236
For diagnosis of code P1236 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 751
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 752
P1235 - P1239: Testing and Inspection P1237
For diagnosis of code P1237 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 753
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 754
P1235 - P1239: Testing and Inspection P1238
For diagnosis of code P1238 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 755
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 763
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 764
P1245 - P1249: Testing and Inspection P1246
For diagnosis of code P1246 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 765
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 776
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 777
P1285 - P1289: Testing and Inspection P1288
For diagnosis of code P1288 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 778
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 779
P1285 - P1289: Testing and Inspection P1289
For diagnosis of code P1289 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 780
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1335 - P1339,
( P1336 P1337 P1338 1335 1336 1337 1338 1339 ) > System Information > System Diagnosis
P1335 - P1339: Testing and Inspection
For diagnosis of code P1336 refer to chart
P1137 - P1400
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 798
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 799
P1380 - P1384: Testing and Inspection P1381
For diagnosis of code P1381 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 800
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 801
P1380 - P1384: Testing and Inspection P1383
For diagnosis of code P1383 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 802
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386
P1385 - P1389: Testing and Inspection P1386
For diagnosis of code P1386 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 > Page 807
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 > Page 808
P1385 - P1389: Testing and Inspection P1388
For diagnosis of code P1388 refer to chart
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1385 - P1389,
( P1386 P1387 P1388 1385 1386 1387 1388 1389 ) > System Information > System Diagnosis > P1386 > Page 809
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1395 - P1399,
( P1396 P1397 P1398 1395 1396 1397 1398 1399 ) > System Information > System Diagnosis
P1395 - P1399: Testing and Inspection
For diagnosis of code P1397 refer to NOTE 17:
NOTE 17: Refer to Charging System and diagnose the charging system concern. See: Starting and
Charging/Charging System/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1137 - P1400
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 818
Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 819
P1400 - P1404: Testing and Inspection P1401
For diagnosis of code P1401 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 820
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 825
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 826
P1405 - P1409: Testing and Inspection P1406
For diagnosis of code P1406 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 827
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 828
P1405 - P1409: Testing and Inspection P1408
For diagnosis of code P1408 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 829
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 830
P1405 - P1409: Testing and Inspection P1409
For diagnosis of code P1409 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 831
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439,
( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436
P1435 - P1439: Testing and Inspection P1436
For diagnosis of code P1436 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439,
( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 836
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439,
( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 837
P1435 - P1439: Testing and Inspection P1437
For diagnosis of code P1437 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439,
( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 838
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 843
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Evaporative Emissions System
DTC Index P0442-P1450
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/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 844
P1450 - P1454: Testing and Inspection P1451
For diagnosis of code P1451 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 845
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 850
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 851
P1460 - P1464: Testing and Inspection P1461
For diagnosis of code P1461 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 852
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 853
P1460 - P1464: Testing and Inspection P1462
For diagnosis of code P1462 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 854
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 855
P1460 - P1464: Testing and Inspection P1463
For diagnosis of code P1463 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 856
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 857
P1460 - P1464: Testing and Inspection P1464
For diagnosis of code P1464 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 858
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 869
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 870
P1475 - P1479: Testing and Inspection P1479
For diagnosis of code P1479 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 871
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 877
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 878
P1500 - P1504: Testing and Inspection P1501
For diagnosis of code P1501 refer to chart
P1401 - P1501
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 879
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 880
P1500 - P1504: Testing and Inspection P1502
For diagnosis of code P1502 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 881
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 882
P1500 - P1504: Testing and Inspection P1504
For diagnosis of code P1504 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 883
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 888
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 889
P1505 - P1509: Testing and Inspection P1507
For diagnosis of code P1507 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 890
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 895
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 896
P1515 - P1519: Testing and Inspection P1517
For diagnosis of code P1517 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 897
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 898
P1515 - P1519: Testing and Inspection P1518
For diagnosis of code P1518 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 899
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 900
P1515 - P1519: Testing and Inspection P1519
For diagnosis of code P1519 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 901
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 905
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539,
( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537
P1535 - P1539: Testing and Inspection P1537
For diagnosis of code P1537 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539,
( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 910
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539,
( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 911
P1535 - P1539: Testing and Inspection P1538
For diagnosis of code P1538 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539,
( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 912
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 916
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 920
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565
P1565 - P1569: Testing and Inspection P1565
For diagnosis of P1565 refer to chart
DTC Index P0500-P0703
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 Cruise Control diagnostic information, See: Cruise Control/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 925
P1565 - P1569: Testing and Inspection P1566
For diagnosis of P1566 refer to chart
DTC Index P0500-P0703
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 Cruise Control diagnostic information, See: Cruise Control/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 926
P1565 - P1569: Testing and Inspection P1567
For diagnosis of P1567 refer to chart
DTC Index P0500-P0703
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 Cruise Control diagnostic information, See: Cruise Control/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569,
( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 927
P1565 - P1569: Testing and Inspection P1568
For diagnosis of P1568 refer to chart
DTC Index P0500-P0703
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 Cruise Control diagnostic information, See: Cruise Control/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 P1572 refer to the system experiencing the problem.
Computers and Control Systems
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 931
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Cruise Control
DTC Index P0500-P0703
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 Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 936
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Emission Control Systems, See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 941
P1635 - P1639: Testing and Inspection P1636
For diagnosis of code P1636 refer to Note 14:
NOTE 14: DTC P1636 indicates the PCM has lost communication with the Inductive Signature
Chip. Replace 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
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 942
P1635 - P1639: Testing and Inspection P1639
For diagnosis of code P1639 refer to Note 7:
NOTE 7: The Vehicle ID (VID) Block must be reprogrammed. For instruction refer to the Flash VID
Block Procedure. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 946
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 951
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 952
P1650 - P1654: Testing and Inspection P1651
For diagnosis of code P1651 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 953
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700
P1700 - P1704: Testing and Inspection P1700
For diagnosis of code P1700 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 959
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 960
P1700 - P1704: Testing and Inspection P1702
For diagnosis of code P1702 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 961
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 962
P1700 - P1704: Testing and Inspection P1703
For diagnosis of code P1703 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 963
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 964
P1700 - P1704: Testing and Inspection P1704
For diagnosis of code P1704 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1700 > Page 965
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
For diagnosis of code P1705 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 970
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 971
P1705 - P1709: Testing and Inspection P1709
For diagnosis of code P1709 refer to chart
P1502 - P176x
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 972
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1711
P1710 - P1714: Testing and Inspection P1711
For diagnosis of code P1711 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > P1711 > Page 977
P1710 - P1714: Testing and Inspection P1714
For diagnosis of code P1714 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 982
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 983
P1715 - P1719: Testing and Inspection P1716
For diagnosis of code P1716 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 984
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 985
P1715 - P1719: Testing and Inspection P1717
For diagnosis of code P1717 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 986
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1740 - P1744: Testing and Inspection P1740
For diagnosis of code P1740 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 991
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 992
P1740 - P1744: Testing and Inspection P1744
For diagnosis of code P1744 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 diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 993
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 system being tested:
Transmission Control
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
Engine Control
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 998
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 999
P1780 - P1784: Testing and Inspection P1781
For diagnosis of code P1781 refer to chart
P177x - P2196
NOTE 13: Go to Transfer Case. See: Transmission and Drivetrain/Transfer Case/Testing and
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1000
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1001
P1780 - P1784: Testing and Inspection P1783
For diagnosis of code P1783 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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
P1900 - P1904: Testing and Inspection
For diagnosis of code P1900 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 1006
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2000 - P2004,
( P2001 P2002 P2003 2000 2001 2002 2003 2004 ) > System Information > System Diagnosis
P2000 - P2004: Testing and Inspection
For diagnosis of code P2004 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2000 - P2004,
( P2001 P2002 P2003 2000 2001 2002 2003 2004 ) > System Information > System Diagnosis > Page 1011
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005
P2005 - P2009: Testing and Inspection P2005
For diagnosis of code P2005 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 1016
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 1017
P2005 - P2009: Testing and Inspection P2006
For diagnosis of code P2006 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 1018
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 1019
P2005 - P2009: Testing and Inspection P2008
For diagnosis of code P2008 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009,
( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 1020
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2010 - P2014,
( P2011 P2012 P2013 2010 2011 2012 2013 2014 ) > System Information > System Diagnosis
P2010 - P2014: Testing and Inspection
For diagnosis of code P2014 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2010 - P2014,
( P2011 P2012 P2013 2010 2011 2012 2013 2014 ) > System Information > System Diagnosis > Page 1024
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019,
( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis
P2015 - P2019: Testing and Inspection
For diagnosis of code P2019 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019,
( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis > Page 1028
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070
P2070 - P2074: Testing and Inspection P2070
For diagnosis of code P2070 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 1033
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 1034
P2070 - P2074: Testing and Inspection P2071
For diagnosis of code P2071 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074,
( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 1035
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2075 - P2079,
( P2076 P2077 P2078 2075 2076 2077 2078 2079 ) > System Information > System Diagnosis
P2075 - P2079: Testing and Inspection
For diagnosis of code P2075 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2075 - P2079,
( P2076 P2077 P2078 2075 2076 2077 2078 2079 ) > System Information > System Diagnosis > Page 1039
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195
P2195 - P2199: Testing and Inspection P2195
For diagnosis of code P2195 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1045
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1046
P2195 - P2199: Testing and Inspection P2196
For diagnosis of code P2196 refer to chart
P177x - P2196
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1047
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1048
P2195 - P2199: Testing and Inspection P2197
For diagnosis of code P2197 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199,
( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 1049
P2195 - P2199: Testing and Inspection P2198
For diagnosis of code P2198 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259,
( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257
P2255 - P2259: Testing and Inspection P2257
For diagnosis of code P2257 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259,
( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257 > Page 1055
P2255 - P2259: Testing and Inspection P2258
For diagnosis of code P2258 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270
P2270 - P2274: Testing and Inspection P2270
For diagnosis of code P2270 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 1060
P2270 - P2274: Testing and Inspection P2271
For diagnosis of code P2271 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 1061
P2270 - P2274: Testing and Inspection P2272
For diagnosis of code P2272 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274,
( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 1062
P2270 - P2274: Testing and Inspection P2273
For diagnosis of code P2273 refer to chart
P2197 - Uxxx
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 1069
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 1070
Accessory Delay Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 1071
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Application and ID
Alarm Module: Application and ID
For further information regarding the Central Security Module, please refer to Body Control Module
/ Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Application and ID
Keyless Entry Module: Application and ID
For further information regarding the Remote Keyless Entry Module, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations
View 151-9
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 1081
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 1082
Parking Assist Control Module: Service and Repair
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal
Positioning Module > Component Information > Application and ID
Pedal Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Application and ID
Keyless Entry Module: Application and ID
For further information regarding the Remote Keyless Entry Module, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Application and ID
Memory Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module >
Component Information > Application and ID
Pedal Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Application and ID
Power Door Lock Control Module: Application and ID
For further information regarding the Computer Operated Locks, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Application and ID
Power Seat Control Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations > Driver Side Front
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations > Driver Side Front > Page 1106
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Passenger Side Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Passenger Side Front > Page 1109
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations
View 151-13
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 1114
Electronic Brake Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 1115
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 1116
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
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: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
NOTE: When installing a new ABS module it must be configured (using vehicle as-built data) and
calibrated. Follow the scan tool directions for the configuration and calibration procedures.
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table. 3. To install, reverse
the removal procedure.
Item 1: Harness Connector Removal Note
1. Disconnect the electrical connector by rotating the protective cover.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 1122
View 151-11
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay > Page 1125
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay > Page 1126
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay
Blower Motor Relay: Testing and Inspection High Speed Fan Control Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 1129
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 1130
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 1131
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 1132
Blower Motor Relay: Testing and Inspection Auxiliary A/C Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 1133
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1137
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1138
Compressor Clutch Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1139
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module
Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 1145
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 1146
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Page 1147
Control Module HVAC: Description and Operation
DATC MODULE
The DATC module: is located in the instrument panel.
- has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed
and diagnostic trouble codes (DTCs).
- utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble
codes (DTCs). These DTCs direct the technician to the inoperative component.
BLOWER MOTOR SPEED CONTROL
The blower speed control: is located on the heater core and evaporator core housing near the blower motor.
- converts low power signals from the DATC module to a high current, variable ground feed for the
blower motor.
- varies the blower motor speed and is controlled by the DATC module software.
- has a delay function to provide a gradual increase or decrease in blower motor speed under all
conditions.
- controls the integral high blower speed relay which is engaged when maximum fan speed is
selected.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Page 1148
Control Module HVAC: Service and Repair
BLOWER MOTOR SPEED CONTROL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1153
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1154
Battery Discharge Protection Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1155
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Locations > Brake Pedal Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Locations > Brake Pedal Relay > Page 1160
Brake Lamp Relay: Locations Stoplamp Isolation Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Locations > Brake Pedal Relay > Page 1161
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Diagrams > Brake Pedal Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Diagrams > Brake Pedal Relay > Page 1164
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay
Brake Lamp Relay: Testing and Inspection Brake Pedal Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay > Page 1167
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay > Page 1168
Brake Lamp Relay: Testing and Inspection Stoplamp Isolation Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay > Page 1169
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 1173
Courtesy Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 1174
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations
View 151-56
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 1178
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 1179
Daytime Running Lamp Control Unit: Service and Repair
DAYTIME RUNNING LAMP (DRL) MODULE
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Page 1183
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Page 1184
Daytime Running Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations > Page 1185
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1189
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1190
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1191
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 1195
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 1196
High Beam Relay: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 1197
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1201
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1202
Horn Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1203
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 1211
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 1212
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 1215
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 1216
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 1217
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 1218
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1221
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1222
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1223
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1224
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1225
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1226
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1227
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1228
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1229
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 1233
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 1234
Turn Signal Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 1235
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection > Page 1240
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection > Page 1244
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 1249
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 1250
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 1253
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 1254
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1257
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1258
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1259
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1260
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 1261
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1266
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1267
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1268
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1269
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1270
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1271
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1272
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1273
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1274
Relay Box: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1275
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 1278
Relay Box: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 1279
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 1280
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 1281
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 1282
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1285
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1286
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1287
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1288
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1289
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1290
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1291
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1292
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1293
Relay Box: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
1294
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Central Security Module
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Central Security Module >
Page 1301
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 1304
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Instructions > Page 1306
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Symbols Part 2
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Instructions > Page 1311
Symbols Part 3
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Instructions > Page 1312
Symbols Part 4
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Instructions > Page 1313
Symbols Part 5
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Systems Overview
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Body Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Body Control Module: Connector Views
Central Security Module
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Driver Seat Module
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Body Control Module: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
59-1
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59-2
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and
Operation
Electronic Throttle Control Module: Description and Operation
Torque Based Electronic Throttle Control (ETC)
Overview
Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output
shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen
II electronic throttle body (replaces throttle cable).
Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by
not coupling the throttle angle to pedal position, which enables various fuel economy schemes and
technologies.
Background "Why Torque Based ETC"
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM
and low manifold vacuum) while still delivering the same torque requested by the driver. It should
be noted that the ETC system includes a wrench light on the instrument cluster that illuminates
when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon"
light.
It also enables many fuel economy/emission improvement technologies such as:
- VCT (deliver same torque during transitions)
- Continuously varying Transmission (CVT)
- Hybrid Electric Vehicle (HEV)
Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other generic benefits of ETC are:
- Eliminate cruise control actuators
- Eliminate ISC Bypass actuator
- Better airflow range
- Packaging (no cable)
Electronic Throttle Body
The Gen II electronic throttle body (Figure 148) has the following characteristics
1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the
throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has
the motor under the bore parallel to the plate shaft. The motor housing is
integrated into the main housing (in general this is more difficult to package). The in-series design
has a separate motor housing that protrudes out and offers more packaging flexibility.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle with no
power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default
angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from
hard-stop angle).
4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75
degree). This hard stop is non-adjustable and is set
to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use
plate sealant. The hole in the plate is not required
with ETB because the required idle airflow is provided by the plate angle, which also is the reason
there is no IAC.
6. The system has two throttle position sensors. Redundant throttle position signals are required for
monitor reasons. TP1 has a negative slope
(increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing
voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control
strategy as the indication of throttle position. The TP assembly requires four wires.
- 5 V Reference Voltage
- Signal Return (ground)
- TP1 voltage with negative voltage slope (5-0)
- TP2 voltage with positive voltage slope (0-5)
Accelerator Pedal Position Sensors (APPS)
The ETC strategy uses pedal position sensors as an input to determine the driver demand.
1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative
slope (increasing angle, decreasing voltage) and
APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal
operation APP1 is used as the indication of pedal
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position by the strategy.
2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires
and pins) between the PCM and APPS assembly.
- 2- (5 V Reference Voltage)
- 2- (Signal Return "ground")
- APP1 voltage with negative voltage slope (5-0)
- APP2 voltage with positive voltage slope (0-5)
- APP3 voltage with positive voltage slope (0-5)
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault.
The PCM knows if a signal is wrong by
calculating where it should be, inferred by the other signals. A safe value will be substituted for a
faulty signal if two out of the three signals are bad.
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Customer Interest: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Technical Service Bulletins for Engine Control Module: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Technical Service Bulletins for Engine Control Module: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 1364
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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Technical Service Bulletins for Engine Control Module: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 1365
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM
Programming Procedures
Engine Control Module: All 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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Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM
Programming Procedures > Page 1370
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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Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM
Programming Procedures > Page 1371
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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Technical Service Bulletins for Engine Control Module: > 03-13-6 > Jul > 03 > Engine Controls - No Start Condition
Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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Technical Service Bulletins for Engine Control Module: > 03-13-6 > Jul > 03 > Engine Controls - No Start Condition > Page
1376
d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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1377
^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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1378
^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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1379
^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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1380
^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming
Procedures
Engine Control Module: All 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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Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming
Procedures > Page 1386
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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Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming
Procedures > Page 1387
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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1388
Engine Control Module: Locations
View 151-7
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1389
View 151-17
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Engine Control Module: Connector Views
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Page 1392
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Page 1393
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Page 1394
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Page 1395
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash
Electrically Eraseable Programmable Read Only Memory
Engine 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 described under Programming the VID
Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635,
P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be
tailored to accommodate various hardware/parameter 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 is one of the main causes for code: P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the 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
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/or incapable of
communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and
execute Module/Parameter reprogramming referring to the manufacturers users manual. Important,
make certain that all parameters are included. Failure to properly program Tire Size in revolutions
per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or
Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be
instructed to contact the "AS BUILT" data center for the information needed to manually update the
VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is
corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician
Society (PTS) web sight 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
accomodate 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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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash
Electrically Eraseable Programmable Read Only Memory > Page 1398
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
2. Disconnect the battery ground cable.
3. Remove the glovebox door assembly.
1 Open the glovebox door.
2 Push in on the sides of the glovebox door to release the retainers.
3 Remove the screws.
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Electrically Eraseable Programmable Read Only Memory > Page 1399
4. Remove the components in the order listed in the illustration and table.
Item 4: Powertrain Control Module (PCM) Removal Note
1. Remove the PCM and bracket as an assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Powertrain Control Module (PCM) Installation Note
1. Install the PCM and bracket as an assembly.
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Main Relay (Computer/Fuel System): Testing and Inspection
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Fuel Pump Relay: Testing and Inspection
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Main Relay (Computer/Fuel System): Testing and Inspection
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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1434
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Component Information > Technical Service Bulletins > Page 1436
Air Bag Control Module: Locations
View 151-21
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View 151-24
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Air Bag Control Module: Diagrams
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Component Information > Service Precautions > Customer Safety Information
Air Bag Control Module: Customer Safety Information
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) has been involved in a collision in which the center tunnel
area has been damaged, inspect the mounting and bracket for deformation. If damaged, 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.
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
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Air Bag Control Module: Technician Safety Information
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for proper air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be 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.
- 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 SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag restraints control module (RCM) retaining nuts is critical for
correct system operation.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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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Air Bag Control Module: Vehicle Damage Warnings
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
can result.
- Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical
connections and damage components.
- Installing a J-nut in place of a weld nut is not a recommended repair.
- Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed
to get the connector into position on the RCM before using the lever to fully seat the connector.
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Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) has been involved in a collision in which the center tunnel
area has been damaged, inspect the mounting and bracket for deformation. If damaged, 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.
N0TE: when installing a new restraints control module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed, erroneous DTCs will result.
The restraints control module carries out the following functions: deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioners to remove slack from the safety belt.
- monitors the 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 instrument cluster module to activate a chime if the air bag indicator is not available
and another SRS fault exists.
The RCM monitors the SRS for possible facts. If a fault is detected while the ignition switch is in the
ON 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 a 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 instrument cluster module 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 lost or damaged during impact. The backup
power supply will deplete its stored energy approximately one minute after the battery ground cable
is disconnected.
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Air Bag Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Air Bag Systems; Testing and Inspection.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure
Air Bag Control Module: Service and Repair General Procedure
Missing Weld Nut
WELD NUT REPAIR - MISSING WELD NUT
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
NOTE: C-pillar repair shown, others similar.
1. Remove the component from where the weld nut is to be repaired.
2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face
will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32
in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding
screw (self-tapping).
5. Set up for the positioning of the weld nut.
1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent
access hole.
2 Position a weld nut, shoulder end up, onto the wire.
3 Position a flat washer onto the wire and secure it so it cannot be pulled off.
6. Plug weld the weld nut into position.
1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the welding wire through and stop against the sheet metal.
2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal.
3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled
previously.
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Component Information > Service and Repair > General Procedure > Page 1448
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the
previously obtained screw.
10. Tighten the attaching screws to specification.
Stripped Weld Nut
WELD NUT REPAIR - STRIPPED WELD NUT
1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and
surrounding area for repair.
- If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn,
then a threaded insert will have to be installed. Follow the instructions with the thread insert repair
kit.
3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit.
Then tap, using an 8 mm by 1.25 bit.
- Do not oversize a 6 mm weld nut by more than 8 mm.
4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit.
Then tap, using a 10 mm by 1.50 bit.
- Do not oversize an 8 mm weld nut by more than 10 mm.
5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7.
Tighten the attaching screws to specification.
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Air Bag Control Module: Service and Repair Removal and Installation
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for proper air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be 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.
- 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 SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag restraints control module (RCM) retaining nuts is critical for
correct system operation.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- 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. 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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure > Page 1450
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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the floor console.
4. Remove the components in the order indicated in the illustration and table.
Item 1: Large Electrical Connector Removal Note
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure > Page 1451
1. Disconnect the large restraints control module (RCM) electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it
stops.
2 Pull out and disconnect the RCM electrical connector.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
Item 1: Large Electrical Connector Installation Note
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure > Page 1452
1. Make sure the connector position assurance lever is in the full release position before attempting
to connect the connector.
2. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
NOTE: The RCM has been removed for clarity.
Position the large RCM electrical connector into the RCM.
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure > Page 1453
3. NOTE: The RCM has been removed for clarity.
Connect the large RCM electrical connector. Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Page 1454
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1459
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1460
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1461
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1462
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1463
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1464
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
1465
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1470
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1471
Starter Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 1472
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations
View 151-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 1478
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 1479
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer
Interest for Control Module: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: Customer Interest A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Control Module: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: All Technical Service Bulletins A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1495
View 151-3
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 1496
Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1501
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1502
Heated Glass Element Relay: Testing and Inspection
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 1503
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Antitheft Mode Switch > Component Information > Locations
View 151-51
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Antitheft Mode Switch > Component Information > Locations > Page 1509
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Antitheft Mode Switch > Component Information > Locations > Page 1510
Antitheft Mode Switch: Service and Repair
ANTI-THEFT ALARM INHIBIT SWITCH
REMOVAL
1. Remove the driver door trim panel. 2. Position the watershield aside.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Anti-Theft Alarm Inhibit Switch Installation Note
1. The anti-theft alarm inhibit switch mark must be positioned towards the harness side of the
switch prior to installation.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood
Sensor/Switch (For Alarm) > Component Information > Locations
View 151-14
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood
Sensor/Switch (For Alarm) > Component Information > Locations > Page 1514
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
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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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1523
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1524
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
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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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1525
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
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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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1526
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
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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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
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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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1532
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
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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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1533
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1534
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 1535
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Outer Left
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 1538
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 1539
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 1540
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Page 1541
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
REMOVAL
1. Remove the rear bumper.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Parking Aid Sensor Removal Note
1. Press the retaining tabs to remove the parking aid sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Assist Switch > Component Information > Locations
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Switch > Component Information > Locations > Page 1545
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Switch > Component Information > Locations > Page 1546
Parking Assist Switch: Service and Repair
PARKING AID SWITCH
REMOVAL
1. Remove the instrument cluster finish panel.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Parking Aid Switch Removal Note
1 Press the retaining tabs to remove the parking aid switch.
INSTALLATION
1. Install in the reverse order of removal.
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Hood Sensor/Switch (For Alarm) > Component Information > Locations
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 1552
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Component Information > Locations
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 1556
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 1557
Power Door Lock Switch: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 1558
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 1559
Power Door Lock Switch: Service and Repair
DOOR LOCK CONTROL SWITCH
NOTE: LH side shown, RH side similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 3: Door Lock Control Switch Removal Note
1. Release the door lock control switch tabs on the switch plate.
INSTALLATION
1. To install, reverse the removal procedure.
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Component Information > Locations
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Component Information > Locations > Page 1563
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1564
Power Mirror Switch: Testing and Inspection
Introduction To Component Testing
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1565
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1566
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
REMOVAL
1. Remove the front door trim panel.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Component Information > Locations > Left
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Component Information > Locations > Left > Page 1571
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Component Information > Diagrams > Left
Power Seat Switch: Diagrams Left
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Component Information > Diagrams > Left > Page 1574
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Component Information > Testing and Inspection > Left
Power Seat Switch: Testing and Inspection Left
Introduction To Component Testing
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Component Information > Testing and Inspection > Left > Page 1577
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Component Information > Testing and Inspection > Left > Page 1578
Power Seat Switch: Testing and Inspection Right
Introduction To Component Testing
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Liftgate Door Lock Switch
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Switch > Component Information > Locations > Liftgate Door Lock Switch > Page 1584
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Liftgate Door Lock Switch
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Switch > Component Information > Diagrams > Liftgate Door Lock Switch > Page 1587
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Switch > Component Information > Diagrams > Page 1588
Power Trunk / Liftgate Lock Switch: Testing and Inspection
Introduction To Component Testing
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Switch > Component Information > Diagrams > Page 1589
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Component Information > Locations > Driver Side
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Component Information > Diagrams > Driver Side
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Component Information > Locations
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Component Information > Locations > Page 1602
Seat Memory Switch: Testing and Inspection
MEMORY SET SWITCH
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, install a new switch; otherwise, return to
the calling Pinpoint Test.
NOTE: Refer to Multimeter User's Manual for testing diodes.
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, install a new switch; otherwise, return to the
calling Pinpoint Test.
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Sunroof / Moonroof Switch: Diagrams
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Sunroof / Moonroof Switch: Testing and Inspection Early Build
Introduction To Component Testing
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Sunroof / Moonroof Switch: Testing and Inspection Late build
Introduction To Component Testing
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Testing and Inspection > Page 1612
Sunroof / Moonroof Switch: Service and Repair
ROOF OPENING PANEL CONTROL SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 3: Roof Opening Panel Control Switch Removal Note
1. Disengage the clips and remove the switch from the overhead console.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 1617
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 1622
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Diagrams > Primary
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Diagrams > Primary > Page 1625
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations > Page 1629
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations
View 151-34
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations > Page 1633
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Accelerometer
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 1: Floor Console-Rear Removal Note 1. If equipped, remove the floor console-rear.
Item 2: Harness Connector Removal Note 1. Fold back the carpeting flap to gain access to the
accelerometer connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
View 151-38
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations > Page 1640
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Removal and Installation
NOTE: The steering wheel rotation sensor is part of the clockspring assembly and is not serviced
separately.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations
View 151-22
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 1647
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-26-3 > Jan > 04 > Brakes - ABS
Lamp ON/DTC's C1235/C1236/C1237 Set
Wheel Speed Sensor: Customer Interest Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-26-3 > Jan > 04 > Brakes - ABS
Lamp ON/DTC's C1235/C1236/C1237 Set > Page 1656
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-26-3 > Jan > 04 > Brakes - ABS
Lamp ON/DTC's C1235/C1236/C1237 Set > Page 1657
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-26-3 > Jan > 04 >
Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's
C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-26-3 > Jan > 04 >
Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 1663
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-26-3 > Jan > 04 >
Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 1664
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page 1670
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: >
03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page 1676
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 1677
Wheel Speed Sensor: Specifications
Front
Wheel speed sensor wire retaining bolt
............................................................................................................................................... 8 Nm
(71 inch lbs.) Wheel speed sensor bolt ...............................................................................................
....................................................................... 8 Nm (71 inch lbs.)
Rear
Wheel speed sensor bolt .....................................................................................................................
.................................................. 27 Nm (20 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Left front
View 151-56
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Left front > Page 1680
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left front > Page 1683
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left front > Page 1684
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left front > Page 1685
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Front Wheel Speed Sensor and Sensor Ring
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the front wheel and tire assembly. 3. Remove
the components in the order indicated in the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 1688
4. To install, reverse the removal procedure.
Item 2: Front Disc Brake Caliper Anchor Plate, Caliper, and Pads Removal Note
1. CAUTION: When removing the front disc brake components, never allow them to hang from the
brake hose.
Using mechanic's wire, secure the front brake components.
Item 3: Front Disc Removal Note 1. Match mark the front disc and front wheel hub flange before
removing the front disc.
Item 4: Harness Connector Removal Note
1. NOTE: The harness connector is located in the engine compartment secured to the fender
apron.
Lower the vehicle.
Item 5: Harness Retainers Removal Note 1. Raise the vehicle on a hoist.
Item 8: Sensor Ring Removal Note 1. The sensor ring is integral to the front wheel hub and bearing
assembly and cannot be serviced.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 1689
Wheel Speed Sensor: Service and Repair Sensor, Rear
Rear Wheel Speed Sensor and Sensor Ring
Removal and Installation
1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. On vehicles with
3-channel ABS, remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure. 5. On vehicles with 4-channel ABS, remove the
components in the order indicated in the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 1690
6. To install, reverse the removal procedure.
Item 5: Sensor Ring Removal Note 1. On vehicles with 3-channel ABS, the sensor ring is attached
to the ring gear and must be removed from the rear differential case. 2. On vehicles with 4-channel
ABS, the sensor ring is attached to the rear axle shaft.
Item 4: O-Ring Installation Note 1. Install a new O-ring.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
View 151-23
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 1694
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 1695
Yaw Rate Sensor: Service and Repair
Yaw Rate Sensor
Removal and Installation
NOTE: The yaw rate sensor is located within the same component as the lateral and longitudinal
accelerometer and must be installed as an assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 1701
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 1702
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1706
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations
Brake Switch (Cruise Control): Locations
View 151-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Page 1711
View 151-26
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Brake Pedal Position Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Brake Pedal Position Switch > Page 1714
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Service Precautions > Technician Safety Information > Page 1717
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Service and Repair > Speed Control Deactivator Switch-With Stability Assist
Brake Switch (Cruise Control): Service and Repair Speed Control Deactivator Switch-With Stability
Assist
SPEED CONTROL DEACTIVATOR SWITCH - WITH STABILITY ASSIST
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Speed Control Deactivator Switch Removal Note
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.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Speed Control Deactivator Switch Installation Note
1. After the deactivator switch is installed, it is necessary to bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Service and Repair > Speed Control Deactivator Switch-With Stability Assist > Page 1720
Brake Switch (Cruise Control): Service and Repair Speed Control Deactivator Switch-Without
Stability Assist
SPEED CONTROL DEACTIVATOR SWITCH - WITHOUT STABILITY ASSIST
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Speed Control Deactivator Switch Removal Note
1. Rotate counterclockwise 45 degrees to remove the speed control deactivator switch.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Speed Control Deactivator Switch Installation Note
1. Press the brake pedal and rotate clockwise 45 degrees to install the speed control deactivator
switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Speed Control Switch-Without Remote Audio/Climate Controls
Cruise Control Switch: Service and Repair Speed Control Switch-Without Remote Audio/Climate
Controls
SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROLS
REMOVAL
1. Remove the air bag.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Speed Control Switch-Without Remote Audio/Climate Controls > Page 1725
Cruise Control Switch: Service and Repair Speed Control Switch-With Remote Audio/Climate
Controls
SPEED CONTROL SWITCH WITH REMOTE AUDIO/CLIMATE CONTROLS
REMOVAL
1. Remove the air bag.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
View 151-35
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 1730
View 151-53
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 1731
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 1732
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
View 151-14
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1737
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1738
Ambient Temperature Sensor / Switch HVAC: Description and Operation
AMBIENT AIR TEMPERATURE SENSOR
The ambient air temperature sensor and bracket: is located in front of the condenser core.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the DATC module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1739
Ambient Temperature Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1740
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
REMOVAL
1. Remove the radiator grille.
2. Remove the components in the order listed in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Description and Operation
Blower Motor Switch: Description and Operation
BLOWER MOTOR SWITCH
The blower motor switch controls blower motor speed by adding or bypassing resistors in the
blower motor switch resistor in all function selector switch positions except OFF.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations
View 151-28
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 1747
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 1748
Cabin Temperature Sensor / Switch: Description and Operation
IN-VEHICLE TEMPERATURE SENSOR
The in-vehicle temperature sensor operates in the following manner: A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the heater core
and evaporator core housing and the in-vehicle temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the heater core and
evaporator core housing air stream to create a suction in the in-vehicle temperature sensor.
- The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 1749
In-Vehicle Temperature Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 1750
Cabin Temperature Sensor / Switch: Service and Repair
IN-VEHICLE TEMPERATURE SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Instrument Cluster Finish Panel Removal Note
1. Remove the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-13
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1755
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1756
High Pressure Sensor / Switch: Description and Operation
HIGH PRESSURE CUTOFF SWITCH
The high pressure cutoff switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures. The high pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure
side of the compressor manifold and tube assembly.
- A valve depressor, located inside the threaded end of the high pressure cutoff switch, presses on
the Schrader valve stem.
- This allows the high pressure cutoff switch to monitor the A/C compressor discharge pressure.
- When the A/C compressor discharge pressure rises, the switch contacts open, disengaging the
A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor.
- It is not necessary to discharge the refrigerant system to remove the high pressure cutoff switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations
Solar Sensor: Locations
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1760
View 151-31
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1761
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1762
Solar Sensor: Description and Operation
SOLAR RADIATION SENSOR
The solar radiation sensor supplies information to the DATC module indicating LH side and RH
side sunload.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Vacuum Sensor / Switch HVAC >
Component Information > Description and Operation
Vacuum Sensor / Switch HVAC: Description and Operation
HEATER CONTROL VALVE VACUUM SWITCH
The heater control valve vacuum switch to control operation of the heater control valve. The heater
control valve vacuum switch: is mounted on the RH side of the heater core and evaporator core housing just below the defrost
door vacuum control motor.
- is actuated by an arm attached to the temperature blend door RH pivot shaft.
- applies vacuum to the heater control valve when the temperature blend door is in the full COOL
position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch
View 151-43
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1771
View 151-42
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1772
Door Switch: Locations Door Ajar Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1773
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1774
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 1775
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 1778
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 1779
Door Switch: Diagrams Door Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 1780
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1789
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1790
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1791
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1792
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1793
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1794
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1800
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1802
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1804
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 1805
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Component Information > Service and Repair
Ambient Light Sensor: Service and Repair
PHOTOCELL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Brake Light Switch: Locations
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Brake Light Switch: Service and Repair
BRAKE PEDAL POSITION (BPP) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Door Switch: Locations Door Ajar Switch
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Door Switch: Diagrams Door Ajar Switch
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Hazard Warning Switch: Diagrams
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Hazard Warning Switch: Testing and Inspection
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Headlamp Dimmer Switch: Diagrams
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Headlamp Dimmer Switch: Testing and Inspection
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Headlamp Switch: Diagrams Multifunction Switch
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Headlamp Switch: Diagrams Main Light Switch
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Headlamp Switch: Testing and Inspection Exterior Lamps
Introduction To Component Testing
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Headlamp Switch: Testing and Inspection Interior Lamps
Introduction To Component Testing
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Headlamp Switch: Service and Repair
HEADLAMP SWITCH
REMOVAL
1. Remove the instrument cluster finish panel.
2. Remove the headlamp switch from the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
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Turn Signal Switch: Diagrams
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Turn Signal Switch: Testing and Inspection
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Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
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Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
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 > Locations
Camshaft Position Sensor: Locations
View 151-73
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1888
View 151-78
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1889
Camshaft Position Sensor: Diagrams
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1890
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
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1891
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
View 151-73
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1895
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 1896
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
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View 151-8
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1900
Crankshaft Position Sensor: Diagrams
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1901
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
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1902
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
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1906
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions
Fuel Tank Pressure Sensor: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
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Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
View 151-55
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View 151-77
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Knock Sensor: Diagrams
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Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Bank Locations
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Bank Locations > Page 1921
Oxygen Sensor: Locations Exhaust System Oxygen Sensor Locations
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Oxygen Sensor: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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and Instructions > Page 1929
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Symbols Part 2
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Symbols Part 3
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Symbols Part 4
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Symbols Part 5
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and Instructions > Page 1934
Systems Overview
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Oxygen Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Oxygen Sensor: Connector Views
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 1944
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1945
Oxygen Sensor: Application and ID
Part 1 Of 2
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1946
Part 2 Of 2
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1947
Oxygen Sensor: Service and Repair
HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. With the vehicle in neutral, position it on a hoist.
2. For the RH side catalytic converter, remove the two bolts and position the heat shield aside.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1948
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 2: Catalyst Monitor Removal Note
1. Using the special tool, remove the catalyst monitor sensors.
Item 3: Heated Oxygen Sensor Removal Note
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1949
1. Using the special tool, remove the heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
Item 3: Heated Oxygen Sensor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensors.
Item 2: Catalyst Monitor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1950
Socket, Exhaust Gas Oxygen Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1955
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1956
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 > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1957
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1958
Pressure Feedback Exhaust Sensor: Locations
View 151-75
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 1959
View 151-76
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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 1960
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1961
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR 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 1962
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1966
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1967
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1968
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 > Locations > Page 1969
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
View 151-6
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1973
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1974
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1975
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 1976
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1982
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1983
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1984
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1985
Pressure Feedback Exhaust Sensor: Locations
View 151-75
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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 1986
View 151-76
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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 1987
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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 1988
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 1989
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-14
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1994
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1995
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
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Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
View 151-20
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2000
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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 > Description and
Operation > Gasoline Fuel System
Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System
The Inertia Fuel Shutoff (IFS) switch (Figure 73) 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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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and
Operation > Gasoline Fuel System > Page 2003
Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System
NATURAL GAS FUEL SYSTEM
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves.
The purpose of the IFS switch is to close the fuel shut-off valves if a crash 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 closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset
before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner
Guide for the location of the IFS.
Reset Instructions
1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak
is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner
Guide).
NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch)
against a spring.
4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking
natural gas.
WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO
NOT RESET THE IFS SWITCH.
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Operation > Page 2004
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Throttle Position Sensor: Locations
View 151-75
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2010
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2011
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2016
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2017
Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2018
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2019
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
View 151-8
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2023
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2024
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2025
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Switches - Ignition System > Ignition Switch > Component Information > Locations
View 151-25
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2031
Ignition Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2032
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2033
Ignition Switch: Service and Repair
IGNITION LOCK CYLINDER
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Ignition Lock Cylinder Removal Note
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
View 151-55
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2037
View 151-77
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2038
Knock Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2039
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Component Information > Locations > Front Impact Severity Sensor
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Front Impact Severity Sensor > Page 2045
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Front Impact Severity Sensor > Page 2046
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Front Impact Severity Sensor > Page 2047
View 151-40
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Front Impact Severity Sensor > Page 2048
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Front Impact Severity Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Front Impact Severity Sensor > Page 2051
Impact Sensor: Diagrams Side Impact Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Front Impact Severity Sensor > Page 2052
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Front Impact Severity Sensor > Page 2053
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Front Impact Severity Sensor > Page 2054
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information > Page 2057
Impact Sensor: Technician Safety Information
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 reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- The tightening torque of the air bag front impact severity sensor retaining bolts is critical for
correct system operation.
- 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.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Customer Safety Information > Page 2058
Impact Sensor: Vehicle Damage Warnings
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service Precautions > Page 2059
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
For these vehicles, the SRS uses up to five satellite sensors in addition to the RCM. The RCM is
mounted to the center tunnel beneath the console. All vehicles will have a front impact severity
sensor and it is located in the front-center of the vehicle, mounted under the lower radiator support.
If the vehicle is equipped with safety canopies, there are four additional side impact sensors. The
four additional sensors are located at the base of each B-pillar and C-pillar. The LH and RH C-pillar
mounted side impact sensors are not interchangeable. Mounting orientation is critical for correct
operation of all impact and rollover sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation
Impact Sensor: Service and Repair Removal and Installation
Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
Special Tool(s)
SPECIAL TOOL(S)
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.
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. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2062
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolts is
critical for correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation
portion of this procedure.
- Make sure the lower radiator support and front impact severity sensor bracket mating surfaces
are clean and debris free.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2063
With all the restraint system diagnostic tools removed prove out the supplemental restraint system
(SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
Item 3: Front Impact Severity Sensor Installation Note
1. Align the locator tab of the front impact severity sensor mounting bracket to the opening in the
lower radiator support sheet metal.
First Row, B-Pillar
SIDE IMPACT SENSOR - FIRST ROW, B-PILLAR
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped
with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or
any other damaged supplemental restraint system (SRS) components whether or not the air bag is
deployed.
NOTE:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2064
- 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.
- The driver side is shown, the passenger side is similar.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the B-pillar trim panel.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. WARNING: The tightening torque of the air bag side impact sensor retaining bolt is critical for
correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2065
To install, reverse the removal procedure
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
8. Check the active restraint system for correct operation.
Item 3: Side Impact Sensor Installation Note
1. Make sure the bolt, washer and clip are in place on the side impact sensor before installing it to
the vehicle.
2. Align the locator pegs to the openings in the B-pillar sheet metal.
Second Row, C-Pillar
SIDE IMPACT SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2066
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped
with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or
any other damaged supplemental restraint system (SRS) components whether or not the air bag is
deployed.
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.
- The RH side is shown, the LH side is similar.
- The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2067
Part 1
Part 2
3. Remove the components in the order indicated in the illustration and table.
Item 4: Quarter Trim Panel Removal Note
1. Pull out on the rear quarter trim panel at the C-pillar to release the retaining clips and access the
C-pillar side impact sensor.
INSTALLATION
1. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for
correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and
Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2068
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
8. Check the active restraint system for correct operation.
Item 7: Side Impact Sensor Installation Note
1 Align the locator tab of the second row side impact sensor mounting bracket to the opening in the
C-pillar sheet metal.
Item 3: Safety Belt Anchor Installation Note
1. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Position the safety belt anchor and install the bolt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2069
Impact Sensor: Service and Repair General Procedures
Missing Weld Nut
WELD NUT REPAIR - MISSING WELD NUT
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
NOTE: C-pillar repair shown, others similar.
1. Remove the component from where the weld nut is to be repaired.
2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face
will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32
in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding
screw (self-tapping).
5. Set up for the positioning of the weld nut.
1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent
access hole.
2 Position a weld nut, shoulder end up, onto the wire.
3 Position a flat washer onto the wire and secure it so it cannot be pulled off.
6. Plug weld the weld nut into position.
1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the welding wire through and stop against the sheet metal.
2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal.
3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled
previously.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Removal and Installation > Page 2070
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the
previously obtained screw.
10. Tighten the attaching screws to specification.
Stripped Weld Nut
WELD NUT REPAIR - STRIPPED WELD NUT
1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and
surrounding area for repair.
- If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn,
then a threaded insert will have to be installed. Follow the instructions with the thread insert repair
kit.
3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit.
Then tap, using an 8 mm by 1.25 bit.
- Do not oversize a 6 mm weld nut by more than 8 mm.
4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit.
Then tap, using a 10 mm by 1.50 bit.
- Do not oversize an 8 mm weld nut by more than 10 mm.
5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7.
Tighten the attaching screws to specification.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Page 2071
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Driver
View 151-52
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Driver > Page 2076
View 151-60
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver > Page 2079
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Page 2080
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the supplemental restraint system (SRS), the front safety belt buckles are equipped with
safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits
called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the
driver and passenger safety belt buckles. The safety belt buckle switches indicate to the restraints
control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this
information in determining the deployment rate of the dual-stage driver and passenger air bag
modules. The RCM also communicates the driver safety belt buckle switch status to the instrument
cluster module, which monitors the information to control the safety belt warning indicator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 2084
Seat Sensor/Switch: Service Precautions
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
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 2085
Seat Sensor/Switch: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a hall-effect sensor located on the driver seat track. The seat track
position sensor informs the restraints control module (RCM) of the driver seat position. Based on
programmed limits, the seat track position sensor will inform the RCM of the driver seat position.
The RCM uses this information in determining the deployment rate of the dual-stage driver air bag
module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 2086
Seat Sensor/Switch: Service and Repair
SEAT POSITION SENSOR
Special Tool(s)
SPECIAL 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.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. NOTE: The seat position sensor is mounted at the LH rear of the seat track.
Position the driver seat forward enough so that upon removal the sensor can clear the magnetic
bar and bracket.
2. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 2087
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable and wait at least one minute.
3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplement restraint system (SRS).
4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Remove the driver seat.
5. Remove the components in the order indicated in the illustration and table.
Item 5: Seat Position Sensor Removal Note
1. NOTE: Make note of the wire harness routing for installation purposes.
Disconnect the seat position sensor electrical connector.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 2088
To install, reverse the removal procedure
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Install the driver seat. After installation, position the driver seat from its forward most position to its rearmost position and
then back again. While positioning the seat, make sure that the seat position sensor, the magnet
and bracket and the wire harness do not come in contact with any other part of the seat that may
cause damage.
3. Connect the battery ground cable.
4. 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.
With the restraint system diagnostic tools installed at all deployable devices, prove out the
supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard /
Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
5. Disconnect the battery ground cable and wait at least one minute.
6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
7. Connect the battery ground cable.
8. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
Item 5: Seat Position Sensor Installation Note
1. NOTE: Route the wire harness as noted during removal.
Connect the seat position sensor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 2089
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 2096
Ignition Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 2097
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 2098
Ignition Switch: Service and Repair
IGNITION LOCK CYLINDER
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Ignition Lock Cylinder Removal Note
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 2102
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 2108
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 2113
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications > Page 2118
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications > Page 2119
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications > Page 2120
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams
Overdrive Switch: Diagrams
Transmission Control Switch (TCS) C/O
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 2129
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2133
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2134
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2135
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2136
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Speed sensor screws ..........................................................................................................................
....................................................... 14 Nm (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 2142
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 2143
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed
Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed
Sensor > Page 2146
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed
Sensor > Page 2147
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed
(OSS) Sensor
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed
(OSS) Sensor > Page 2150
1. Remove the OSS sensor.
1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the OSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed
(OSS) Sensor > Page 2151
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed
(OSS) Sensor > Page 2152
1. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the transmission.
^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the TSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed
(OSS) Sensor > Page 2153
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed
(OSS) Sensor > Page 2154
1. Remove the intermediate shaft speed sensor.
1 Remove the intermediate shaft speed sensor screw.
2 Remove the intermediate shaft speed sensor from the transmission.
^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the intermediate shaft speed sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 solenoid body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2160
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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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 2161
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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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 2162
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2163
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2164
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2165
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2166
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2167
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2168
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2169
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2170
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2171
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2172
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2173
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2174
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2175
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2176
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2177
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2178
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2179
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2180
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 solenoid body. - The PCM uses the TFT signal to help determine shift
scheduling, torque converter clutch operation and pressure control requirements.
It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature.
The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift
schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits
torque converter clutch (TCC) operation at low transmission fluid temperatures and use to
determine pressure control (PC) solenoid operations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 2185
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch
Power Window Switch: Locations Window Adjust Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2191
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2192
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 2193
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2196
Power Window Switch: Diagrams Window Adjust Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 2197
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2200
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2201
Power Window Switch: Testing and Inspection Power window Switch
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2202
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 2203
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Window Control Switch Bezel Removal Note
1. Lift the front of the window control switch bezel upward to release the front hold-down clip. 2.
Slide the window control switch bezel forward to release the rear tab.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
View 151-15
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 2208
View 151-16
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 2209
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2213
Windshield Washer Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2214
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2215
Windshield Washer Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 2216
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2220
Wiper Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2221
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2222
Wiper Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2223
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Alignment: Specifications Alignment Specifications
Front
Caster
LH ........................................................................................................................................................
................................ 5.1 degrees ± 1.0 degrees RH ...........................................................................
............................................................................................................. 5.3 degrees ± 1.0 degrees
Total/Split .............................................................................................................................................
.............................. -0.2 degrees ± 0.4 degrees
Camber
LH ........................................................................................................................................................
.............................. -0.5 degrees ± 0.8 degrees RH ............................................................................
.......................................................................................................... -0.5 degrees ± 0.8 degrees
Total/Split .............................................................................................................................................
.................................. 0 degrees ± 0.8 degrees
Toe (positive value is toe-in, negative value is toe-out)
LH ........................................................................................................................................................
............................ 0.10 degrees ± 0.25 degrees RH ...........................................................................
......................................................................................................... 0.10 degrees ± 0.25 degrees
Total/Split .............................................................................................................................................
.......................... 0.20 degrees ± 0.25 degrees
Rear
Camber
LH ........................................................................................................................................................
.............................. -0.9 degrees ± 0.8 degrees RH ............................................................................
.......................................................................................................... -0.9 degrees ± 0.8 degrees
Total/Split .............................................................................................................................................
................................. 0 degrees ± 0.8 degrees
Toe (positive value is toe-in, negative value is toe-out)
LH ........................................................................................................................................................
............................ 0.10 degrees ± 0.25 degrees RH ...........................................................................
........................................................................................................ 0.10 degrees ± 0.25 degrees
Total/Split .............................................................................................................................................
.......................... 0.20 degrees ± 0.25 degrees
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 2229
Alignment: Specifications General Specifications
Ride Height
Front ....................................................................................................................................................
................. 17 mm (0.68 inch) ± 8 mm (0.32 inch) Rear ......................................................................
............................................................................................... 91 mm (3.64 inch) ± 11 mm (0.44
inch)
Vehicle lean (side-to-side height differences)
Front-maximum ...................................................................................................................................
.................................................. 7 mm (0.28 inch) Rear-maximum .....................................................
................................................................................................................................. 8 mm (0.32 inch)
Wheel Track
Wheel track ..........................................................................................................................................
............................................... 0.6 mm (0.02 inch)
Dogtracking
Dogtracking-maximum (centerline of front tires compared to centerline of rear tires)
........................................................................ 30 mm (1.18 inch)
Ball joint end play
Lower ball joint-maximum vertical
...................................................................................................................................................... 0.8
mm (0.03 inch) Upper ball joint-maximum vertical
...................................................................................................................................................... 0.8
mm (0.03 inch)
Cleaners-Wheel
Custom Bright Metal Cleaner 8A-19522-A
............................................................................................................................................
ESR-M5B194-B
Tire balance weight
Maximum balance weight (total of inner and outer wheel flange); 170 g (6.0 oz.)
Tire Inflation
Tires; See safety certification sticker located on driver door jamb.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 2230
Alignment: Specifications Torque Specifications
Wheel nuts ...........................................................................................................................................
................................................. 135 Nm (100 ft. lbs.) Tire pressure monitoring sensor valve stem
nut ..................................................................................................................................... 7 Nm (62
inch lbs.) Tire pressure monitoring system module screws
.................................................................................................................................... 7 Nm (62 inch
lbs.)
Front Suspension
Wheel hub-to-wheel knuckle bolts
..................................................................................................................................................... 112
Nm (83 ft. lbs.) Tie-rod end nut ............................................................................................................
......................................................................... 70 Nm (52 ft. lbs.) Axle-to-wheel hub nut ..................
.................................................................................................................................................... 250
Nm (184 ft. lbs.) Upper ball joint nut ....................................................................................................
........................................................................... 55 Nm (41 ft. lbs.) Upper arm-to-frame nuts ............
...................................................................................................................................................... 150
Nm (111 ft. lbs.) Lower ball joint nut ....................................................................................................
..................................................................... 175 Nm (129 ft. lbs.) Lower arm-to-frame flag bolt and
nut (forward attachment) ............................................................................................................ 400
Nm (295 ft. lbs.) Lower arm-to-frame nuts (rearward attachment)
.............................................................................................................................. 150 Nm (111 ft.
lbs.) Shock absorber upper mounting plate-to-frame nuts (M8)
................................................................................................................... 30 Nm (22 ft. lbs.) Shock
absorber-to-lower arm bolt and flag nut
................................................................................................................................. 350 Nm (258 ft.
lbs.) Stabilizer bar bracket-to-frame bolts
.................................................................................................................................................... 70
Nm (52 ft. lbs.) Stabilizer bar-to-link nut ..............................................................................................
......................................................................... 70 Nm (52 ft. lbs.) Anti-lock brake sensor bolt ...........
........................................................................................................................................................ 18
Nm (13 ft. lbs.) Caliper anchor plate-to-wheel knuckle bolts
....................................................................................................................................... 112 Nm (83
ft. lbs.) Caliper-to-anchor plate bolts ....................................................................................................
............................................................ 32 Nm (24 ft. lbs.)
Rear Suspension
Upper ball joint-to-wheel knuckle pinch bolt and nut
........................................................................................................................... 90 Nm (66 ft. lbs.)
Upper arm-to-frame bolt and nut
........................................................................................................................................................
133 Nm (98 ft. lbs.) Upper arm-to-frame bolts and flag nuts
................................................................................................................................................ 80 Nm
(59 ft. lbs.) Upper arm bushing-to-upper arm nut
.................................................................................................................................................. 120
Nm (89 ft. lbs.) Lower arm-to-frame flag bolts and nuts
............................................................................................................................................ 175 Nm
(129 ft. lbs.) Lower arm-to-wheel knuckle bolt and nut
........................................................................................................................................ 150 Nm (111
ft. lbs.) Stabilizer bar-to-link nut ...........................................................................................................
............................................................ 25 Nm (18 ft. lbs.) Stabilizer bar bracket-to-frame nuts
...................................................................................................................................................... 55
Nm (41 ft. lbs.) Shock absorber upper mounting plate-to-frame nuts(M8)
.................................................................................................................... 30 Nm (22 ft. lbs.) Shock
absorber-to-lower arm bolt and flag nut
................................................................................................................................. 250 Nm (184 ft.
lbs.) Shock absorber-to-upper mounting plate nut(M12)
.............................................................................................................................. 50 Nm (37 ft. lbs.)
Toe link-to-frame nut ...........................................................................................................................
................................................. 80 Nm (59 ft. lbs.) Toe link-to-wheel knuckle pinch bolt and nut
...................................................................................................................................... 90 Nm (66 ft.
lbs.) Toe link adjustment locknut .........................................................................................................
........................................................ 70 Nm (52 ft. lbs.) Parking brake cable bracket-to-lower arm
bolt ....................................................................................................................................... 12 Nm (9
ft. lbs.) Axle-to-wheel hub retainer nut
.........................................................................................................................................................
275 Nm (203 ft. lbs.) Rear caliper bolts ...............................................................................................
................................................................................... 32 Nm (24 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2231
Alignment: Description and Operation
Suspension System
The front caster and camber are adjusted by means of removing set shims at the upper control
arm-to-frame mounting bolts and installing washers (W-705040-S426) to allow the arm to be
adjusted in the frame slots. A caster split adjustment can be made by turning an adjustment bolt
located on the RH lower arm rearward frame mountings. Front toe is adjusted by the use of the
front wheel spindle tie-rod. The rear camber is adjusted by removing the set shim from the
rearward lower control arm to frame mounting bolt and installing a washer (W-705040-S426) to
allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe
link.
Camber
Part 2 Of 3
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2232
the vehicle the best directional stability characteristics when loaded and driven. The caster setting
is not related to tire wear.
Toe
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.
Ride Height
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2233
Front Ride Height Measurement
Rear Ride Height Measurement
Wheel Track
Wheel Track
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2234
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.
Wander Wander is the tendency of the vehicle to require frequent, random left and right steering
wheel corrections to maintain a straight path down a level road.
Shimmy Shimmy, as observed by the driver, is large consistent, rotational oscillations of the
steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually
experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes
or irregularities in the road surface.
Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with
various road surfaces and observed by the driver as small rotational oscillations of the steering
wheel.
Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor
return of the steering wheel to center after a turn or the steering correction is completed.
Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be
overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does
with hands off the steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment
Alignment: Service and Repair Camber and Caster Adjustment
Wheel Alignment
Front Camber and Caster Adjustment
1. NOTE: The upper arm-to-frame mounting bolts have set shims that must be replaced with
washers (W-705040-S426) to allow for adjustment of
the arm in the frame slot. The vehicle should be supported by the lower arm to ease movement of
the upper arm in the slot.
Remove the nuts and the shims. ^
Discard the nuts and shims.
^ Install new washers (W-705040-S426) and nuts and snug the nuts.
2. To adjust the caster and camber, refer to the chart.
^ Make adjustments that require moving the front and the rear of the upper arm equally.
3. Tighten the nuts.
4. NOTE: A caster split adjustment can be made by turning an adjustment bolt located on the RF
lower arm rearward frame mounting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2237
Loosen the nuts and adjust the bolt clockwise to decrease the RH caster or counterclockwise to
increase the RH caster.
5. Check and, if necessary, adjust the front toe.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2238
Alignment: Service and Repair Rear Camber Adjustment
Rear Camber Adjustment
1. NOTE: The lower arm rearward mounting bolt has a set shim that must be removed and
replaced with a washer (W-705040-S426) to allow for
the adjustment of the arm in the frame slot.
Remove the nut and the set shim. ^
Discard the nut and set shim. Install the washer (W-705040-S426) and the nut and snug the nut.
2. NOTE: A prybar may be used between the lower arm and the frame pocket to aid in moving the
arm outward.
To decrease the camber, move the lower arm outward.
3. NOTE: Adjustable pliers may be used to aid in moving the arm inward.
To increase the camber, move the lower arm inward.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2239
4. Tighten the nut. 5. Check and, if necessary, adjust the rear toe.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2240
Alignment: Service and Repair Toe Adjustment
Front
Front Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight ahead" position using a suitable holding device.
3. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is
rotated.
Remove the clamps.
4. Loosen the nuts.
^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads.
5. Rotate the front wheel spindle tie-rods. 6. Start the engine and recenter the steering wheel.
^ Recheck the toe settings and adjust if necessary.
7. CAUTION: Make sure to hold the tie-rod end stationary with a wrench while tightening the nut or
damage to the boot can occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2241
Tighten the nuts.
8. Install the clamps.
Rear
Rear Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight ahead" position using a suitable holding device.
3. Loosen the nuts.
^ Clean and lubricate the nut(s) and rear toe link threads.
4. While holding the toe link spindle tie-rod, rotate the toe link adjuster.
5. NOTE: Make sure the toe settings are not disturbed while tightening the nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2242
While holding the adjuster, tighten the nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information > Page 2249
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 2250
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-R0087 OR EQUIVALENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 2251
Fuel Pressure Test Port: Service and Repair
FUEL PRESSURE RELIEF VALVE
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C Underhood - Buzz or Flutter Noise
Air Cleaner Housing: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C Underhood - Buzz or Flutter Noise > Page 2260
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 > Mar > 03 >
A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 > Mar > 03 >
A/C - Underhood - Buzz or Flutter Noise > Page 2266
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Page 2267
Air Cleaner Housing: Service and Repair
AIR CLEANER ASSEMBLY
REMOVAL
1. Remove the splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Page 2268
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 2273
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 2274
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications > Page 2278
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and
Indicators > System Information > Specifications
Timing Marks and Indicators: Specifications
Ignition Timing .....................................................................................................................................
................................................................ 10° BTDC
NOTE: Base timing only.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2289
Ignition Cable: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2290
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2291
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2292
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications
Spark Plug: Specifications
Spark Plug
Refer to Vehicle Emissions Control Information (VECI) decal for spark plug information.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2296
Spark Plug: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2297
Spark Plug: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2298
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2299
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2300
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2304
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of 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 at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2305
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 at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 05-17-8 > Sep > 05 > A/C - Drive Belt Chirp When A/C Compressor Engages
Drive Belt: Customer Interest A/C - Drive Belt Chirp When A/C Compressor Engages
TSB 05-17-8
09/05/05
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a chirp
noise from the front end accessory drive (FEAD) belt when the A/C compressor is engaging.
ACTION Verify concern. Replace the A/C compressor clutch pulley, and set the clutch air gap to
the specification listed in this TSB (the Workshop Manual specification is being updated). Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Recover the refrigerant.
2. Remove the A/C compressor. Refer to Workshop Manual Section 412.
3. Using the special tool 412-098, hold the A/C clutch plate and remove the clutch nut.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C clutch hub spacer.
6. Remove the A/C compressor pulley snap ring.
CAUTION
DO NOT USE AIR TOOLS. DAMAGE TO THE A/C CLUTCH PULLEY OR A/C COMPRESSOR
MAY RESULT.
7. Using the special tool 412-001, remove the A/C clutch pulley.
8. Install the new A/C clutch pulley using special tool 412-109.
9. Reinstall the A/C compressor pulley snap ring.
10. Reinstall the original A/C clutch hub spacer.
11. Reinstall the A/C clutch disc and hub.
12. Using special tool 412-098, hold the A/C clutch plate and reinstall the A/C clutch nut. Tighten to
14 lb-ft (19 N.m).
13. Measure and adjust the clutch air gap to 0.010 - 0.024" (0.254 - 0.610 mm), by adding or
removing A/C clutch disc and hub spacers.
14. Reinstall the A/C compressor.
15. Recharge the system.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051708A 2002-2005 1.1 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 05-17-8 > Sep > 05 > A/C - Drive Belt Chirp When A/C Compressor Engages > Page 2314
Explorer/Mountaineer 4.0L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708B 2002-2005 1.2 Hrs.
Explorer/Mountaineer 4.6L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708C 2003-2005 Aviator: 1.4 Hrs.
Replace The A/C Compressor Clutch Pulley (Do Not Use With 19700A, 19700A4, 19700AZU,
19700R)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D784 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 05-17-8 > Sep > 05 > A/C - Drive Belt Chirp When A/C Compressor Engages
Drive Belt: All Technical Service Bulletins A/C - Drive Belt Chirp When A/C Compressor Engages
TSB 05-17-8
09/05/05
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a chirp
noise from the front end accessory drive (FEAD) belt when the A/C compressor is engaging.
ACTION Verify concern. Replace the A/C compressor clutch pulley, and set the clutch air gap to
the specification listed in this TSB (the Workshop Manual specification is being updated). Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Recover the refrigerant.
2. Remove the A/C compressor. Refer to Workshop Manual Section 412.
3. Using the special tool 412-098, hold the A/C clutch plate and remove the clutch nut.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C clutch hub spacer.
6. Remove the A/C compressor pulley snap ring.
CAUTION
DO NOT USE AIR TOOLS. DAMAGE TO THE A/C CLUTCH PULLEY OR A/C COMPRESSOR
MAY RESULT.
7. Using the special tool 412-001, remove the A/C clutch pulley.
8. Install the new A/C clutch pulley using special tool 412-109.
9. Reinstall the A/C compressor pulley snap ring.
10. Reinstall the original A/C clutch hub spacer.
11. Reinstall the A/C clutch disc and hub.
12. Using special tool 412-098, hold the A/C clutch plate and reinstall the A/C clutch nut. Tighten to
14 lb-ft (19 N.m).
13. Measure and adjust the clutch air gap to 0.010 - 0.024" (0.254 - 0.610 mm), by adding or
removing A/C clutch disc and hub spacers.
14. Reinstall the A/C compressor.
15. Recharge the system.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051708A 2002-2005 1.1 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 05-17-8 > Sep > 05 > A/C - Drive Belt Chirp When A/C Compressor Engages > Page
2320
Explorer/Mountaineer 4.0L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708B 2002-2005 1.2 Hrs.
Explorer/Mountaineer 4.6L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708C 2003-2005 Aviator: 1.4 Hrs.
Replace The A/C Compressor Clutch Pulley (Do Not Use With 19700A, 19700A4, 19700AZU,
19700R)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D784 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 2321
Component Locations 4.0L
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Inspection and Verification
1. Verify the customer's concern by operating the engine to duplicate the condition.
Visual Inspection Chart
2. Inspect to determine if any of the mechanical concerns apply. 3. Inspect for drive belt
cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms. GO to
Symptom Chart. See: Symptom Related Diagnostic Procedures
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. A new drive belt should be installed if chunking occurs.
V-Ribbed Belt With Cracks (Acceptable)
V-Ribbed Serpentine Drive Belt with Cracks Across Backing
V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable)
V-Ribbed Serpentine Drive Belt with Chunks of Rib Missing
5. If the concern(s) remains after inspection, determine the symptoms. GO to Symptom Chart.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2324
Drive Belt: Symptom Related Diagnostic Procedures
Symptom Chart
Part 1 Of 2
Part 2 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2325
Drive Belt: Component Tests and General Diagnostics
Drive Belt-Misalignment
CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the
drive bed 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 necessary.
^ Check all accessories, mounting brackets and drive belt tensioner, for any interference that would
prevent the component from mounting correctly. 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2326
Drive Belt: Service and Repair
Accessory Drive Belt, Tensioner and Pulley
Removal and Installation
1. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Part 2 Of 2
2. To install, reverse the removal procedure.
Item 1: Accessory Drive Belt Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2327
1. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
1 Rotate the accessory drive belt tensioner counterclockwise.
2 Remove the accessory drive belt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise >
Page 2337
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter
Noise
Air Cleaner Housing: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter
Noise > Page 2343
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Page 2344
Air Cleaner Housing: Service and Repair
AIR CLEANER ASSEMBLY
REMOVAL
1. Remove the splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Page 2345
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service
Precautions
Evaporative Canister Filter: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service
Precautions > Page 2352
Evaporative Canister Filter: Service and Repair
DUST SEPARATOR
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist. 3. Remove the evaporative (EVAP) canister
solenoid.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Leak test the evaporative emission system. 3. Carry
out the evaporative emission repair drive cycle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications >
Mechanical Specifications
Fluid Filter - A/T: Mechanical Specifications
Transmission fluid filter screws
............................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications >
Mechanical Specifications > Page 2357
Fluid Filter - A/T: Fluid Type Specifications
Fluid Filter Kit .......................................................................................................................................
................................................... XC3Z-7B I55-AA
Fluid Filter ............................................................................................................................................
..................................................... XC3Z-7B155-BA
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2358
Fluid Filter - A/T: Service and Repair
Fluid Pan, Gasket and Filter
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
NOTE: Install a new transmission fluid filter.
1. With the vehicle in PARK, position on a hoist. 2. Remove the components in the order indicated
in the illustration and table.
3. To install, reverse the removal procedure. 4. Partially fill the transmission.
Item 6: Transmission Fluid Pan Filter Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2359
1. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly sealed on the filter.
Lubricate the seals and install the transmission fluid filter.
Item 3: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Item 2: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 2364
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 2365
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications
Oil Bypass Filter ..................................................................................................................................
........................................................ 13 N (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2378
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2379
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2385
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2386
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Heater Hose: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237
Set
Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's
C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Heater Hose: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237
Set > Page 2392
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Heater Hose: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237
Set > Page 2393
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Heater Hose: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237
Set > Page 2399
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Heater Hose: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237
Set > Page 2400
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Climate Control
Heater Hose: Service and Repair Auxiliary Climate Control
Front Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE - FRONT
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Drain the engine coolant.
3. Remove the RH running board brackets.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Climate Control > Page 2403
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine coolant level.
Rear Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE - REAR
REMOVAL
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Drain the engine coolant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Climate Control > Page 2404
3. Remove the spare tire.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine coolant level.
Item 12 & 11: Auxiliary Heater Line Installation Note
1. Clean and lubricate the coolant hoses with plain water only if needed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Climate Control > Page 2405
Heater Hose: Service and Repair Main Climate Control
HEATER CONTROL VALVE AND HEATER HOSES
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. If removing any component
other than the heater control valve, drain the engine coolant. 3. If removing the heater control valve
only, clamp off the heater hoses at the heater control valve inlet and outlet.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Climate Control > Page 2406
4. Remove the components in the order indicated in the illustration and table. To remove individual
components, carry out only the given steps.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From Vehicle
Rear
Hose/Line HVAC: Customer Interest A/C - Moan/Buzz/Groan Noise From Vehicle Rear
TSB 04-24-6
12/13/04
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles built before
10/15/2004 equipped with rear air conditioning may exhibit a whistle/moan/groan/buzz noise
coming from the rear evaporator core area. This condition is usually intermittent and is typically
present on light throttle application.
ACTION Inspect A/C lines for possible grounding. If the source of the noise cannot be pinpointed
through normal diagnostics, replace the rear thermostatic expansion valve (TXV).
SERVICE PROCEDURE
NOTE
FOR STEPS 1, 5 AND 6, REFER TO WORKSHOP MANUAL SECTION 412-00.
1. Recover the refrigerant.
2. Disconnect the LH quarter trim panel and gently pull cover back to expose rear lxv. Refer to
Workshop Manual Section 501-01.
NOTE
IT IS NOT NECESSARY TO REMOVE THE LH QUARTER TRIM PANEL FROM THE VEHICLE.
3. Remove the rear TXV.
4. To install, reverse the removal procedure. Torque the rear TXV nut to 17 lb-ft (23 N.m).
5. Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042406A Replace The Rear 1.5 Hrs.
Thermostatic Expansion Valve (Includes Time To Inspect Lines And Recover, Evacuate And
Charge The Refrigerant System)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From Vehicle
Rear > Page 2415
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 41
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Hose/Line HVAC: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page
2420
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From
Vehicle Rear
Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Buzz/Groan Noise From Vehicle Rear
TSB 04-24-6
12/13/04
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles built before
10/15/2004 equipped with rear air conditioning may exhibit a whistle/moan/groan/buzz noise
coming from the rear evaporator core area. This condition is usually intermittent and is typically
present on light throttle application.
ACTION Inspect A/C lines for possible grounding. If the source of the noise cannot be pinpointed
through normal diagnostics, replace the rear thermostatic expansion valve (TXV).
SERVICE PROCEDURE
NOTE
FOR STEPS 1, 5 AND 6, REFER TO WORKSHOP MANUAL SECTION 412-00.
1. Recover the refrigerant.
2. Disconnect the LH quarter trim panel and gently pull cover back to expose rear lxv. Refer to
Workshop Manual Section 501-01.
NOTE
IT IS NOT NECESSARY TO REMOVE THE LH QUARTER TRIM PANEL FROM THE VEHICLE.
3. Remove the rear TXV.
4. To install, reverse the removal procedure. Torque the rear TXV nut to 17 lb-ft (23 N.m).
5. Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042406A Replace The Rear 1.5 Hrs.
Thermostatic Expansion Valve (Includes Time To Inspect Lines And Recover, Evacuate And
Charge The Refrigerant System)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From
Vehicle Rear > Page 2426
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 41
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter
Noise
Hose/Line HVAC: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter
Noise > Page 2431
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
> Main Climate Control
Hose/Line HVAC: Description and Operation Main Climate Control
REFRIGERANT LINES
NOTE: Installation of a new receiver/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 receiver/drier.
The compressor manifold and tube assembly is attached to the A/C compressor, is sealed 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 high pressure cutoff switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C high pressure
cutoff switch can be removed without discharging the A/C system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
> Main Climate Control > Page 2434
Hose/Line HVAC: Description and Operation Auxiliary Climate Control
UNDERBODY AUXILIARY A/C LINES
The underbody auxiliary A/C lines carry refrigerant to the auxiliary A/C evaporator inlet line, and
away from the auxiliary A/C evaporator outlet line. The auxiliary underbody lines have the following
characteristics. The underbody auxiliary A/C evaporator inlet line consists of two separately serviceable pieces.
- The fore auxiliary A/C evaporator inlet line carries high pressure refrigerant liquid from the
condenser to evaporator line to the aft auxiliary A/C evaporator inlet line.
- The aft auxiliary A/C evaporator inlet line carries high pressure refrigerant liquid from the fore
auxiliary A/C evaporator inlet line to the auxiliary evaporator inlet.
- The underbody auxiliary A/C evaporator outlet line consists of two separately serviceable pieces.
- The aft auxiliary A/C evaporator outlet line carries refrigerant vapor from the auxiliary A/C
evaporator outlet to the fore auxiliary A/C evaporator outlet line.
- The fore auxiliary A/C evaporator outlet line carries refrigerant vapor from the aft auxiliary A/C
evaporator inlet line to the manifold and tube assembly.
UNDERBODY HEATER LINES
The underbody auxiliary heater lines have the following features. The underbody auxiliary heater inlet line consists of two separately serviceable assemblies.
- The fore underbody auxiliary heater inlet line is a steel tube assembly that carries coolant from
the front heater core inlet line to the aft underbody auxiliary heater inlet line.
- The aft underbody auxiliary heater inlet line carries coolant from the fore underbody heater inlet
line to the auxiliary heater core.
- The aft underbody auxiliary heater inlet line consists of a steel tube with formed rubber hoses at
each end. The rubber hoses are attached and sealed to the tube using constant tension pop
clamps.
- The aft underbody auxiliary heater outlet line carries coolant from the auxiliary heater core to the
fore underbody auxiliary heater outlet line.
- The aft underbody auxiliary heater outlet line consists of a steel tube with formed rubber hoses at
each end. The rubber hoses are attached and sealed to the tube using constant tension pop
clamps.
- The fore underbody auxiliary heater outlet line is a steel tube assembly that carries coolant from
the aft underbody heater outlet line to the front heater core outlet line.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control
Hose/Line HVAC: Service and Repair Auxiliary Climate Control
Front Auxiliary Evaporator Outlet and Inlet Line
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT
REMOVAL
NOTE:
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3.
Remove the RH running board brackets.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control > Page 2437
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Rear Auxiliary Evaporator Outlet and Inlet Line
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR
REMOVAL
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control > Page 2438
NOTE:
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3.
Remove the spare tire.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control > Page 2439
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control > Page 2440
Hose/Line HVAC: Service and Repair Main Climate Control
Evaporator Outlet Line
EVAPORATOR OUTLET LINE
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the air cleaner and air cleaner outlet tube. 2. Recover the refrigerant. 3. Disconnect the
RH wheel speed sensor electrical connector.
4. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control > Page 2441
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Condenser to Evaporator Line
CONDENSER TO EVAPORATOR LINE
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the air cleaner and air cleaner outlet tube. 2. Remove the suction accumulator. 3.
Recover the refrigerant.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Auxiliary Climate Control > Page 2442
3. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure line fitting-to-pump ................................................................................................................
.................................................... 65 Nm (48 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity
Specifications
Brake Fluid: Capacity Specifications
Fill to the line on the reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity
Specifications > Page 2451
Brake Fluid: Fluid Type Specifications
Brake fluid ............................................................................................................................................
...................................................................... DOT 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum
and Temperature Specifications
Coolant: Pressure, Vacuum and Temperature Specifications
Cooling System Pressure Test
Cooling system ....................................................................................................................................
.................................................... 138 kPa (20 psi)
Radiator Cap Pressure Test
Cap ......................................................................................................................................................
...................................... 89 - 124 kPa (13 - 18 psi)
Thermostat Opening Temperature
Starts to open ......................................................................................................................................
.......................................................... 90°C (194°F) Fully open ...........................................................
........................................................................................................................................ 105°C
(210°F)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum
and Temperature Specifications > Page 2456
Coolant: Capacity Specifications
Engine Coolant Capacity
Without Auxiliary Climate Control
..........................................................................................................................................................
16.3 qts (15.4L)
With Auxiliary Climate Control .............................................................................................................
.................................................. 18.2 qts (17.2L)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Pressure, Vacuum
and Temperature Specifications > Page 2457
Coolant: Fluid Type Specifications
Engine Coolant Types
Use Motorcraft Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine
Coolant (yellow-colored).
Caution: Do not mix coolant types. Use the engine coolant type originally equipped with your
vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
......................................................... 12.7 qts (12.0L)
Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler
size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should
be checked by a qualified technician.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 2462
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Type ...............................................................................................................................................
Motorcraft MERCON V Automatic Transmission Fluid
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment
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 specified for this transmission. Do not use
supplemental transmission fluid additives, treatments or clean agents. The use of these materials
may affect transmission operation and result in damage to internal transmission components.
CAUTION: Always refer to the instructions supplied with the 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 line. This will
help remove any foreign material trapped in the fluid coolers.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2465
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2466
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2467
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2468
Fluid - A/T: Service and Repair Transmission Fluid Level Check
Transmission Fluid Level Check
NOTE: This drain and fill procedure is referenced from TSB # 02-20-3 and applies to 5R55N,
5R55S, and 5R55W Automatic Transmissions.
Part 2 Of 2
Special Tool(s)
Fluid Fill Reference
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2469
NOTE: Left side of case is shown.
1. Using the scan tool (WDS), monitor the Transmission Fluid Temperature (TFT) using PID TFT.
2. Start the vehicle.
3. NOTE: Engine idle speed is approximately 650 rpm.
While proceeding with this procedure, run the engine until the transmission fluid temperature is
between 27°C - 49°C (80°F - 120°F).
4. Move the range selector lever slowly through each gear, stopping in each position and allowing
the transmission to engage. 5. Place the range selector lever in the PARK position. 6. With the
engine running, position the vehicle on a hoist and set it as close to level as possible.
7. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug
using a 3/16-inch Allen key.
8. Install the special tool into the pan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2470
9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is
clean.
Fill the special tool with clean automatic transmission fluid.
10. Hang the special tool under the vehicle. Position it upright and close to the transmission.
11. Connect the special tools.
^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid
Level and Fill Plug Adapter at the bottom of the transmission fluid pan.
12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from
the special tool. Fluid will immediately start flowing
out of the special tool into the transmission fluid pan.
13. Add one pint of transmission fluid into the fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the end of the
hose.
14. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the
transmission is full. If no fluid drains back, more fluid will
need to be added. Repeat steps 12 and 13.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Drain and
Refill W/Automated Equipment > Page 2471
15. Once the transmission is full, place a hand vacuum pump on the open end of the
vacuum/pressure hose of the special tool and apply vacuum to the
system. This will pull out any extra fluid trapped in the system and direct it into the container.
16. Allow the fluid to drain. Make sure that the fluid temperature is between 27°C - 49°C (80°F 120°F). When the fluid comes out as a thin stream
or drip, the fluid is at the correct level.
17. Reinstall the small (center) fluid level indicating plug using a 3/16 inch Allen key. 18. Check the
operation of the transmission by moving the range selector lever slowly through each gear,
stopping in each position and allowing the
transmission to engage.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information > Page 2476
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information > Page 2477
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Rear Axle..............................................................................................................................................
.......................................................1.65 L (3.5 pints)*
Additive Friction Modifier......................................................................................................................
................................................0.12 L (0.25 pints)**
Front Axle..............................................................................................................1.54 L (2.7 pints)
(9.56 mm (0.38 in) below the bottom of the filler hole)
* Fill to the bottom of the filler hole, then add 0.425 L (0.9 pint) through the ABS sensor hole.
** Install friction modifier before installing axle lubricant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 2482
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
REAR AXLE* SAE 75W-140 High Performance Rear Axle Lubricant Ford P/N .................................
..............................................................................................................................................................
...... XY-75W140-QL Ford Specification ..............................................................................................
........................................................................................ WSL-M2C192-A
FRONT AXLE SAE 80W-90 Premium Rear Axle Lubricant Ford P/N .................................................
......................................................................................................................................................
XY-80W90-QL Ford Specification .......................................................................................................
............................................................................... WSP-M2C197-A
Additive Friction Modifier XL-3 Ford P/N .............................................................................................
........................................................................................................................... XL-3 Ford
Specification ........................................................................................................................................
............................................... EST-M2C118-A
* If fluid is required, replace the original FEHP lubricant with 75W-140. Remove the old tag and
install a new tag.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 2487
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page
2488
Fluid - Transfer Case: Service and Repair
Transfer Case Draining and Filling
1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed.
NOTE: The fluid level must be just below the fill plug.
Remove the fill plug and check the fluid level. ^
If the fluid is below the proper level, fill the transfer case with automatic transmission fluid.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 2493
Engine Oil: Fluid Type Specifications
Engine Oil ................................................................................................................ Super Premium
SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2498
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications
Power Steering Fluid: Capacity Specifications
Fill between the MIN and MAX lines on the reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications > Page 2501
Power Steering Fluid: Fluid Type Specifications
Lubricant ..............................................................................................................................
Motorcraft MERCON (R) Multi-Purpose Transmission Fluid
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Capacity without auxiliary climate control.............................................................................................
..........................................................0.96 kg (34 oz)
Capacity with auxiliary climate control..................................................................................................
..........................................................1.59 kg (56 oz)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 2506
Refrigerant: Fluid Type Specifications
Refrigerant Type ..................................................................................................................................
.......................................................... R134a, YN-19
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2507
Refrigerant: Service Precautions
CAUTION:
- If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12
recovery/recycling equipment.
- Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If
the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all
the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other
cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful
in removing small traces of contamination from the air that might affect the leak detector.
- Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the
engine.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2508
Refrigerant: Description and Operation
REFRIGERANT SYSTEM DYE
Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will
dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye
after flushing or filtering the refrigerant system because a new suction accumulator is installed as
part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if
more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation,
hose rupture or other damage.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection
Refrigerant: Testing and Inspection Electronic Leak Detection
ELECTRONIC LEAK DETECTION
Refrigerent Leak Detector
SPECIAL TOOL(S)
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate
this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner,
or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is
very helpful in removing small traces of contamination from the air that might affect the leak
detector.
1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant.
- Repair the system.
- Test the system for normal operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 2511
Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection
FLUORESCENT DYE LEAK DETECTION
Special Tool(s)
SPECIAL TOOL(S)
NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the
refrigerant system from the factory. The location of leaks can be pinpointed by the bright
yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist,
make sure to inspect each component, line, and fitting in the refrigerant system for a leak.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 2512
1. Check for leaks using the special tool.
- Inspect all components, lines, and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate
and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of
fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the
leak with the special tool.
Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
NOTE:
- Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers
instructions on evacuation of any non-condensable gasses from the hoses.
- Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service
center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way
check valve that will prevent refrigerant system recovery and evacuation.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
1. Install an R-134a A/C refrigerant service center or a manifold and gauge set.
2. Verify that the valves on the special tool are closed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 2513
3. Fill the special tool reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the special tool
between the low-pressure service gauge port valve and the R-134a refrigerant service center or
manifold gauge set. 5. Open all valves and inject the fluorescent dye into the refrigerant system 6.
When fluorescent dye injection is complete, close all valves. 7. Recover the refrigerant from the
R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure
service gauge port valve and the R- 134a A/C refrigerant service center or manifold
gauge set.
Fluorescent Dye Injection - Using a Dye Injector Loop Kit
NOTE:
- Before using the R-134a fluorescent dye injector for the first time, refer to the equipment
manufacturers instructions on evacuation of non-condensable gasses from the hoses.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C.
1. Verify that the valves on the special tool are closed.
2. Fill the special tool reservoir with 7 ml (0.25 oz) of fluorescent dye. 3. Install the special tool
between the high-pressure and low-pressure service gauge port valves.
4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt
before starting the engine.
Start the engine.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 2514
5. Open the high-pressure service valve.
6. Open the special tool valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the special tool to equalize
with the suction side of the refrigerant system.
8. NOTE: Close the valves on the special tool while the A/C compressor is operating.
Close the valves on the special tool.
9. NOTE: Leave all valves on the special tool closed when not in use.
Disconnect the high-pressure and low-pressure service valves and remove the special tool from
the vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure
Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure
AIR CONDITIONING (A/C) SYSTEM RECOVERY
Special Tool(s)
SPECIAL TOOL(S)
Refrigerant System Recovery
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2517
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant.
2. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set.
Connect an R-134a A/C service center to the low and high-pressure service gauge port valves.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system
refrigerant, close the service center inlet valve (if 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 vacuum
does not decrease, disconnect the refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains
stable for two minutes. 7. Carry out the required repairs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2518
Refrigerant: Service and Repair Evacuation and Charging
AIR CONDITIONING (A/C) SYSTEM EVACUATION AND CHARGING
Special Tool(s)
SPECIAL TOOL(S)
Refrigerant System Evacuation
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2519
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
1. Connect an R134a service center to the low- and high-pressure service gauge port valves. 2.
Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum
and as close to 101.1 kPa (30 in-Hg) as
possible. Continue to operate the vacuum pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that
the system vacuum is held. If vacuum is not held
for five minutes, leak test the system, service the leak, and evacuate the system again.
Refrigerant System Charging
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the
system. 2. Charge the system with the specified amounts of refrigerant oil and refrigerant. 3. When
no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation.
Adjust the blower motor speed to the
maximum and allow the remaining refrigerant to be drawn into the system. Continue to add
refrigerant into the system until the specified weight of R-134a has been added. Close the charging
cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the
low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2520
Refrigerant: Service and Repair Identifying Refrigerants
REFRIGERANT IDENTIFICATION TESTING
Delux A/C Refrigerant Analyzer
SPECIAL TOOL(S)
1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior
to recovering or charging the refrigerant system.
Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample
for testing.
2. The diagnostic tool will display one of the following:
- If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" light emitting
diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will
be displayed on the digital display.
- If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and
a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12,
R-22, and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user
of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will also
be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is
98% or greater. The diagnostic tool eliminates the
effect of air when determining the refrigerant sample content because air is not considered a
contaminant, although air can affect A/C system performance. when the diagnostic tool has
determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air
concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air
purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
5. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
or R-12 recovery/recycling equipment.
Recover any contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 2521
Refrigerant: Service and Repair Handling of Contaminated Refrigerants
CONTAMINATED REFRIGERANT HANDLING
1. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your
recovery/recycling equipment.
Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to
other vehicles.
- If this equipment is not available, contact an A/C service facility in your area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customer's initial concern.
3. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured
for correct oil system matching.
The suction accumulator/drier cannot be cleaned. A new suction accumulator/drier must be
installed.
Remove the suction accumulator/drier.
4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction
accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8.
Dispose of contaminated refrigerant according to all federal, state and local regulations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2522
Refrigerant: Tools and Equipment
Refrigerent Leak Detector
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2523
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2524
Delux A/C Refrigerant Analyzer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Capacity without auxiliary climate control.............................................................................................
.............................................................266 ml (9 oz)
Capacity with auxiliary climate control..................................................................................................
...........................................................384 ml (13 oz)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 2529
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil
............................................................................................................................................. PAG
Refrigerant Compressor Oil, YN-12-C
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2530
Refrigerant Oil: Service Precautions
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed, some of the 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2531
Refrigerant Oil: Service and Repair
REFRIGERANT OIL ADDING
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed, some of the 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. NOTE: Service A/C compressors are shipped without compressor oil.
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 Refrigerant Compressor Oil (R-134a
Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 Refrigerant Compressor Oil (R-134a
Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B
into the new A/C compressor.
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 Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA
(Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft
YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction
accumulator/drier inlet tube.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2532
4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft
YN-12-C) 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 Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Washer Fluid > Component Information > Specifications > Capacity
Specifications
Washer Fluid: Capacity Specifications
Fill to the line on the reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fluids > Washer Fluid > Component Information > Specifications > Capacity
Specifications > Page 2537
Washer Fluid: Fluid Type Specifications
Windshield Washer Fluid Type .........................................................................................................
Motorcraft Ultra-Clear Windshield Washer Fluid
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair
Brake Bleeding: Service and Repair
Brake System Bleeding
Special Tool(s)
Material
Master Cylinder Bleeding 1. Connect one end of a clear, flexible hose to the master cylinder
bleeder screw. Submerge the other end in a container partially filled with the
specified brake fluid.
2. Have an assistant pump and then hold firm pressure on the brake pedal. 3. Open the master
cylinder bleeder screw until brake fluid flows into the container. 4. When the fluid stops flowing,
close the bleeder screw. 5. Repeat Steps 2-4 until there are no air bubbles in the brake fluid. 6.
Have an assistant pump and then hold firm pressure on the brake pedal. 7. Loosen a master
cylinder tube fitting at the anti-lock brake hydraulic control unit. 8. When fluid stops flowing from the
fitting, tighten the fitting. 9. Repeat Steps 6-8 until there are no air bubbles in the brake fluid.
10. Repeat Steps 6-9 on the remaining master cylinder tube fitting.
Brake Caliper Bleeding
NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened
part of the system.
1. Connect one end of a clear flexible hose to the caliper screw. Submerge the other end in a
container partially filled with the specified brake fluid. 2. Have an assistant pump and then hold firm
pressure on the brake pedal. 3. Open the caliper bleeder screw until brake fluid flows into the
container. 4. When fluid stops flowing, close the bleeder screw. 5. Repeat previous three steps until
there are no air bubbles in the brake fluid.
Anti-Lock Brake System Hydraulic Control Unit Bleeding
NOTE: This procedure is only required when a new hydraulic control unit is installed.
1. Connect the scan tool and follow the ABS system bleed instructions. 2. Use the caliper bleed
procedure to bleed the system. Begin at the RH rear caliper.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions >
Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions >
Technician Safety Information > Page 2545
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2548
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2549
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2550
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2551
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2552
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2553
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2554
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2555
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2556
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2557
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2558
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2559
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2560
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2561
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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2562
10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2563
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2564
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2565
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2566
- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2567
10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2568
12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2569
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2570
Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2571
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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2572
3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2573
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2574
11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Air Bag Disarming and Arming > Page 2575
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Air Bag Disarming and Arming > Page 2576
All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2577
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2578
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2579
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2580
13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2581
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2582
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2583
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2584
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Page 2585
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2591
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2592
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2593
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2594
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2595
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2596
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2597
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2598
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2599
Fuse: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2600
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2603
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2604
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2605
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2606
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2607
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2608
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2609
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2610
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2611
Fuse: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2612
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2617
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2618
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2619
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2620
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2621
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2622
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2623
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2624
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2625
Fuse Block: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2626
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views
Fuse Block: Connector Views
Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2629
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2630
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2631
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2632
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Connector Views > Page 2633
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2636
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2637
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2638
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2639
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2640
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2641
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2642
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2643
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2644
Fuse Block: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2645
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2650
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2651
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2652
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2653
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2654
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2655
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2656
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2657
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2658
Relay Box: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2659
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 2662
Relay Box: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 2663
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 2664
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 2665
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 2666
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2669
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2670
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2671
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2672
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2673
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2674
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2675
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2676
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2677
Relay Box: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2678
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions
Low Tire Pressure Indicator: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2684
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2685
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2686
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2687
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2688
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2689
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2690
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2691
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2692
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2693
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2694
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2695
Low Tire Pressure Indicator: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2696
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2697
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2698
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2699
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2700
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2701
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2702
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 2703
Low Tire Pressure Indicator: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
118-1
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) (Figure 17) 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 18).
- 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 Symptom Charts.
- 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.
Malfunction Indicator Lamp (MIL)
CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
Change Oil Soon/Oil Change Required Message
Displayed when the engine oil life remaining is 5 percent or less. When oil life left is between 5%
and 0% the CHANGE OIL SOON message will be displayed. When oil life left reaches 0% the OIL
CHANGE REQUIRED message will be displayed.
An oil change is required whenever indicated by the message center. USE ONLY
RECOMMENDED ENGINE OILS.
To reset the oil monitoring system to 100% after each oil change [approximately 8000 km (5000
miles) or 180 days] perform the following:
1. Press the SETUP control to access the System Check function.
2. Press and release the RESET control to display "OIL LIFE XX% HOLD RESET NEW".
3. Press and hold the RESET control for 2 seconds to display "IF NEW OIL HOLD RESET".
4. Press and hold the RESET control to display "OIL LIFE SET TO 100%". Your oil life is now
reset.
To reset the oil monitoring system to your personalized oil life:
1. Press the SETUP control to access the System Check function.
2. Press and release the RESET control to display "OIL LIFE XX% HOLD RESET NEW".
3. Press and hold the RESET control for 2 seconds to display "IF
NEW OIL HOLD RESET".
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair > Page 2710
4. Release the RESET control momentarily, then press RESET and SETUP controls at the same
time to activate a service mode which will display
"OIL LIFE XX% RESET TO ALTER".
5. Press RESET until you find your personalized OIL LIFE XX%. 6. With your personalized OIL
LIFE XX% displayed, press SETUP to continue the system check.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the
vehicle to move.
- Make sure to properly locate jack stands under the frame to prevent the vehicle from falling.
CAUTION: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack.
- Position the jack to avoid contact with the fuel tank.
Jacking Points
Jacking Points
1. The front jacking points are indicated by a cut-out in the frame, located behind the front tire and
wheel.
2. 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.
The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel.
LIFTING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 2715
Lifting Points
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
- Position the hoist adapters to avoid contact with the fuel tank.
The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
lifting equipment before use.
Position the hoist directly under the frame rails.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Locations
View 151-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Locations > Page 2720
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Locations > Page 2721
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Specifications > Page 2726
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Specifications > Page 2727
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Specifications > Page 2728
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions
Low Tire Pressure Indicator: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2734
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2735
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2736
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2737
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2738
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2739
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2740
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2741
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2742
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2743
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2744
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2745
Low Tire Pressure Indicator: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2746
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2747
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2748
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2749
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2750
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2751
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2752
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Diagrams > Diagram Information and Instructions > Page 2753
Low Tire Pressure Indicator: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
118-1
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Locations
View 151-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Locations > Page 2757
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >
Component Information > Locations > Page 2758
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Specifications > Page 2762
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Specifications > Page 2763
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Specifications > Page 2764
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 2773
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 2774
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 2775
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2781
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2782
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2783
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
Wheel Bearing: Customer Interest Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
> Page 2792
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
> Page 2793
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
> Page 2794
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise
Wheel Bearing: All Technical Service Bulletins Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 2800
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 2801
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 2802
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 2803
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tires are off of the ground.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the wheel and tire assembly.
Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire from the front wheel bearings. If movement exists, a new bearing must be
installed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Front
Special Tool(s)
1. On 4x4 vehicles, loosen the axle retainer nut
2. NOTE: The wheel speed sensor electrical connectors are located in the engine compartment
secured to the fender aprons
Disconnect the wheel speed sensor.
3. Remove the wheel and tire assembly.
4. To remove individual suspension components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2806
5. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2807
6. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and
table. 7. To install, reverse the removal procedure.
Item 1: Axle-to-Wheel Hub Nut Removal Note
1. Remove the nut and, using the special tool, separate the outboard CV joint from the wheel hub.
Item 2: Speed Sensor Harness Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2808
1. Detach the wheel speed sensor harness from the brake hose
Item 5: Brake Caliper, Pads and Anchor Plate Removal Note
1. CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose can
occur.
Position the caliper, pads and anchor plate aside
Item 10: Tie-Rod End-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod from the wheel knuckle
Item 11: Lower Ball Joint-to-Wheel knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle
Item 12: Upper Ball Joint-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2809
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
Item 27: Lower Arm Installation Note 1. Check and, if necessary, align the front end.
Item 24: Lower Arm-to-Frame Nut (forward mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 21: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Item 16: Upper Arm Installation Note 1. Check and, if necessary, align the front end.
Item 13: Wheel Knuckle Installation Note 1. Check and, if necessary, align the front end.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2810
Wheel Bearing: Service and Repair Rear
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2811
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2812
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2813
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2814
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 2815
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Suspension
Axle-to-wheel hub nut ..........................................................................................................................
............................................. 250Nm (184 ft. lbs.)
Rear Suspension
Axle-to-wheel hub retainer nut
.........................................................................................................................................................
275 Nm (203 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Wheel nuts ...........................................................................................................................................
.................................................. 135Nm (100 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the
vehicle to move.
- Make sure to properly locate jack stands under the frame to prevent the vehicle from falling.
CAUTION: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack.
- Position the jack to avoid contact with the fuel tank.
Jacking Points
Jacking Points
1. The front jacking points are indicated by a cut-out in the frame, located behind the front tire and
wheel.
2. 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.
The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel.
LIFTING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
2826
Lifting Points
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
- Position the hoist adapters to avoid contact with the fuel tank.
The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
lifting equipment before use.
Position the hoist directly under the frame rails.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Cam Timing System
Overview
There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are
Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded.
The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A
intake phase shifting system will move the intake cam in the advance direction. The other two
possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally
as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The
systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At
idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and
Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module
(PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems
provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems
have the added benefit of improve torque. In addition a VCT system will eliminate the need for an
external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished
by controlling the overlap in valve opening between the intake valve opening and exhaust valve
closing. Increased vehicle reliability is achieved with the elimination of the EGR system.
Variable Cam Timing
Variable Cam Timing System
The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid,
a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of
equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1).
Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1
tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP
signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control
module) with crankshaft positioning information in 10 degree increments (Figure 130).
1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant
temperature), CMP, TP (throttle position), MAF
(Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine
speeds and closed throttle) the PCM controls camshaft position based on air and coolant
temperatures. During part and wide open throttle, camshaft position is determined by engine RPM,
load and throttle position. The VCT system will not operate until the engine is at normal operating
temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired
camshaft position. It will continually update the VCT solenoid duty cycle until desired
positioning is achieved. A difference between the desired and actual camshaft position represents
a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the
camshaft in a default position if a fault is detected.
5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear
piston motion to a rotational motion that
advances or retards the camshaft.
Hardware
Variable Cam Timing (VCT) Solenoid Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Page 2833
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the
solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100%
represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by
dithering (oscillating) the solenoid valve duty near 50%.
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The VCT unit assembly (Figure 132) 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, a pressure
differential occurs forcing the piston to move. This movement 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 2837
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of 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 at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 2838
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 at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications
Camshaft Bearing: Specifications
Camshaft bearing caps bolts.
Stage 1 ................................................................................................................................................
................................................. 6 Nm (53 inch lbs.) Stage 2 ...............................................................
................................................................................................................................... 16 Nm (12 ft.
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
..................................................... 85 Nm (63 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications
Camshaft: Specifications
Camshaft
Theoretical valve lift @ 0 lash .............................................................................................................
................................................................... 12 mm Lobe lift ................................................................
......................................................................................................................... 6.584 mm (0.259 inch)
Allowable lobe lift loss .........................................................................................................................
......................................... 0.127 mm (0.005 inch) Journal diameter
.................................................................................................................................................. 27.935
- 27.96 mm (1.099 - 1.101 inch) Camshaft journal bore inside diameter
.................................................................................................................... 28.0 - 28.03 mm (1.102 1.104 inch) Camshaft journal-to-bearing clearance
.................................................................................................................... 0.04 - 0.095 mm (0.002 0.004 inch) Runout ..............................................................................................................................
............................................................... 0.05 mm (0.002 inch) End play
..............................................................................................................................................................
0.075 - 0.185 mm (0.0003 - 0.007 inch)
RH Camshaft Bearing Cap Bolts
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 the bolts in the sequence shown in two stages.
Tighten the bolts to 6 Nm (53 inch lbs.). Tighten the bolts to 16 Nm (12 ft. lbs.).
LH Camshaft Bearing Cap Bolts
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 the bolts in the sequence shown in two stages.
Tighten the bolts to 6 Nm (53 inch lbs.). Tighten the bolts to 16 Nm (12 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 2849
Camshaft: Description and Operation
VARIABLE CAM TIMING SYSTEM
Overview
There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are
Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded.
The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A
intake phase shifting system will move the intake cam in the advance direction. The other two
possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally
as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The
systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At
idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and
Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module
(PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems
provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems
have the added benefit of improve torque. In addition a VCT system will eliminate the need for an
external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished
by controlling the overlap in valve opening between the intake valve opening and exhaust valve
closing. Increased vehicle reliability is achieved with the elimination of the EGR system.
Variable Cam Timing
Variable Cam Timing System
The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid,
a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of
equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1).
Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1
tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP
signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control
module) with crankshaft positioning information in 10 degree increments (Figure 132).
1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant
temperature), CMP, TP (throttle position), MAF
(Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine
speeds and closed throttle) the PCM controls camshaft position based on air and coolant
temperatures. During part and wide open throttle, camshaft position is determined by engine RPM,
load and throttle position. The VCT system will not operate until the engine is at normal operating
temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired
camshaft position. It will continually update the VCT solenoid duty cycle until desired
positioning is achieved. A difference between the desired and actual camshaft position represents
a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the
camshaft in a default position if a fault is detected.
5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear
piston motion to a rotational motion that
advances or retards the camshaft.
Hardware
Variable Cam Timing (VCT) Solenoid Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 2850
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 133) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the
solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100%
represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by
dithering (oscillating) the solenoid valve duty near 50%.
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The VCT unit assembly (Figure 134) 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, a pressure
differential occurs forcing the piston to move. This movement 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH
Camshaft: Service and Repair Camshaft, Valve Springs and Valve Seals-RH
Camshaft, Valve Springs and Valve Seals-RH
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers.
2. NOTE: This step is necessary for camshaft removal only.
Remove the cooling fan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2853
3. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2854
Part 2 Of 2
4. To install, reverse the removal procedure.
5. NOTE: This step is necessary for camshaft installation only.
Install the cooling fan.
6. Install the LH and RH valve covers.
Item 2: Camshaft Roller Follower Removal Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2855
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Items 3, 4 and 5: Valve Spring Retainer Keys, Valve Spring Retainers and Valve Springs Removal
Note 1. Position the piston of the cylinder being serviced at top dead center (TDC). 2. Hold the
valves in the cylinder head.
^ Remove the spark plug of the cylinder being serviced.
^ Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Items 7-12: Camshaft Sprocket, Main Bearing Cap Mounting Bolts, Oil Supply Tube, Main Bearing
Caps and Camshaft Removal Note
1. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is
serviced.
Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2856
3. NOTE: The special tool must be installed on the damper and should contact the engine block,
this positions the piston at TDC.
Install the special tools.
4. Install the special tools on the rear of the RH cylinder head and tighten the top two clamp bolts to
10 Nm (89 inch lbs.)
5. CAUTION: The RH camshaft sprocket is a LH threaded bolt.
Using the special tool, loosen the camshaft sprocket bolt.
6. Remove the special tools.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2857
7. Remove the bolt and position the camshaft sprocket aside.
8. 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.
Items 12-7: Camshaft, Main Bearing Caps, Oil Supply Tube, Main Bearing Cap Mounting Bolts,
and Camshaft Sprocket Installation Note
1. 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 the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
2. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2858
Install the camshaft sprocket and loosely install the bolt.
3. The camshafts must be retimed.
Item 6: Valve Seals Installation Note
1. Using the special tool, install the valve stem seal.
Item 5-3: Valve Spring, Valve Spring Retainers, and Valve Spring Retainer Keys Installation Note
1. 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, install the valve spring retainer keys, the valve springs and the retainers.
Item 2: Roller Follower Installation Note
1. NOTE: The roller followers must be installed in their original position.
Using the special tool install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2859
Camshaft: Service and Repair Camshaft, Valve Springs and Valve Seals-LH
Camshaft, Valve Springs and Valve Seals-LH
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers.
2. NOTE: This step is necessary for camshaft removal only.
Remove the cooling fan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2860
3. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2861
Part 2 Of 2
4. To install, reverse the removal procedure.
5. NOTE: This step is necessary for camshaft installation only.
Install the cooling fan.
6. Install the LH and RH valve covers.
Item 2: Camshaft Roller Follower Removal Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2862
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Items 3, 4 and 5: Valve Spring Retainer Keys, Valve Spring Retainers and Valve Springs Removal
Note 1. Position the piston of the cylinder being serviced at Top Dead Center (TDC). 2. Hold the
valves in the cylinder head.
^ Remove the spark plug of the cylinder being serviced.
^ Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Items 7-12: Camshaft Sprocket, Main Bearing Cap Mounting Bolts, Oil Supply Tube, Main Bearing
Caps and Camshaft Removal Note
1. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is
serviced.
Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2863
3. NOTE: The special tool must be installed on the damper and should contact the engine block,
this positions the piston at TDC.
Install the special tool.
4. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to
10 Nm (89 inch lbs.).
5. Loosen the bolt.
6. Remove the special tools.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2864
7. Remove the bolt and position the camshaft sprocket aside.
8. 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.
Items 12-7: Camshaft, Main Bearing Caps, Oil Supply Tube, Main Bearing Cap Mounting Bolts,
and Camshaft Sprocket Installation Note
1. 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 the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2865
2. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time
Install the camshaft sprocket and loosely install the bolt.
3. The camshafts must be retimed.
Item 6: Valve Seals Installation Note
1. Using the special tool, install the valve stem seal.
Item 5, 4, and 3: Valve Spring, Valve Spring Retainer, Valve Spring Retainer Keys Installation Note
1. 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, install the valve spring, valve spring retainer, and the valve spring retainer
keys.
Item 2: Roller Follower Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2866
1. NOTE: The roller followers must be installed in their original position.
Using the special tool, install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Camshaft Roller Follower and Hydraulic Lash Adjuster
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers. 2. Remove the components in the order indicated.
3. To install, reverse the removal procedure. 4. Install the LH and RH valve covers.
Item 1: Camshaft Roller Followers Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Page 2870
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Item 2: Hydraulic Lash Adjuster Removal Note
1. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position.
Remove the hydraulic lash adjusters.
Item 11: Camshaft Roller Followers Installation Note
1. NOTE: The roller followers must be installed in their original position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Page 2871
Using the special tool, install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Camshaft Roller Follower and Hydraulic Lash Adjuster
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers. 2. Remove the components in the order indicated.
3. To install, reverse the removal procedure. 4. Install the LH and RH valve covers.
Item 1: Camshaft Roller Followers Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 2875
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Item 2: Hydraulic Lash Adjuster Removal Note
1. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position.
Remove the hydraulic lash adjusters.
Item 11: Camshaft Roller Followers Installation Note
1. NOTE: The roller followers must be installed in their original position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 2876
Using the special tool, install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Cam Timing System
Overview
There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are
Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded.
The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A
intake phase shifting system will move the intake cam in the advance direction. The other two
possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally
as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The
systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At
idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and
Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module
(PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems
provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems
have the added benefit of improve torque. In addition a VCT system will eliminate the need for an
external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished
by controlling the overlap in valve opening between the intake valve opening and exhaust valve
closing. Increased vehicle reliability is achieved with the elimination of the EGR system.
Variable Cam Timing
Variable Cam Timing System
The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid,
a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of
equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1).
Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1
tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP
signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control
module) with crankshaft positioning information in 10 degree increments (Figure 130).
1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant
temperature), CMP, TP (throttle position), MAF
(Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine
speeds and closed throttle) the PCM controls camshaft position based on air and coolant
temperatures. During part and wide open throttle, camshaft position is determined by engine RPM,
load and throttle position. The VCT system will not operate until the engine is at normal operating
temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired
camshaft position. It will continually update the VCT solenoid duty cycle until desired
positioning is achieved. A difference between the desired and actual camshaft position represents
a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the
camshaft in a default position if a fault is detected.
5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear
piston motion to a rotational motion that
advances or retards the camshaft.
Hardware
Variable Cam Timing (VCT) Solenoid Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Page 2880
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the
solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100%
represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by
dithering (oscillating) the solenoid valve duty near 50%.
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The VCT unit assembly (Figure 132) 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, a pressure
differential occurs forcing the piston to move. This movement 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft >
Component Information > Specifications
Balance Shaft: Specifications
Balance Shaft Bolts .............................................................................................................................
..................................................... 27 Nm (20 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain >
Component Information > Specifications
Balance Shaft Chain: Specifications
Balance Shaft Chain Guide .................................................................................................................
.................................................. 10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting rod bearing bore diameter
....................................................................................................... 56.82 mm - 56.84 mm (2.237 inch
- 2.238 inch) Connecting rod bearing-to-crank shaft clearance
.................................................................................................. 0.008 - 0.061 mm (0.0003 - 0.0024
inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications
Connecting rod pin bore diameter
......................................................................................................................... 23.958 - 23.976 mm
(0.943 - 0.944 inch) Connecting rod length (center-to-center)
.......................................................................................................... 145.965 - 146.035 mm (5.746 5.749 inch) Connecting rod maximum allowed bend
............................................................................................ 0.0125 mm (0.00049 inch) per 25.4 mm
(1.000 inch) Connecting rod maximum allowed twist
................................................................................................ 0.038 mm (0.0015 inch) per 25.4 mm
(1.000 inch) Connecting rod side clearance
............................................................................................................................... 0.092 - 0.268 mm
(0.0036 - 0.0106 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
Main bearing journal diameter
.................................................................................................................................. 56.980 - 57.0
mm (2.243 - 2.244 inch) Main bearing journal maximum taper
.............................................................................................................................................. 0.008
mm (0.0003 inch) Main bearing journal maximum out-of-round
.................................................................................................................................. 0.008 mm
(0.0003 inch) Main bearing journal-to-cylinder block clearance
................................................................................................ 0.008 - 0.062 mm (0.0003 - 0.0024
inch) Connecting rod journal diameter
................................................................................................................................. 53.98 - 54.0 mm
(2.125 - 2.126 inch) Connecting rod journal maximum taper
........................................................................................................................................... 0.008 mm
(0.0003 inch) Connecting rod journal maximum out-of-round
.............................................................................................................................. 0.008 mm (0.0003
inch) Crankshaft maximum end play
.................................................................................................................................... 0.05 - 0.32 mm
(0.002 - 0.0126 inch)
Crankshaft Main Bearing Cap bolts
..........................................................................................................................................................
97 Nm (72 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Main bearing journal diameter
.................................................................................................................................. 56.980 - 57.0
mm (2.243 - 2.244 inch) Main bearing journal maximum taper
.............................................................................................................................................. 0.008
mm (0.0003 inch) Main bearing journal maximum out-of-round
.................................................................................................................................. 0.008 mm
(0.0003 inch) Main bearing journal-to-cylinder block clearance
................................................................................................ 0.008 - 0.062 mm (0.0003 - 0.0024
inch) Connecting rod journal diameter
................................................................................................................................. 53.98 - 54.0 mm
(2.125 - 2.126 inch) Connecting rod journal maximum taper
........................................................................................................................................... 0.008 mm
(0.0003 inch) Connecting rod journal maximum out-of-round
.............................................................................................................................. 0.008 mm (0.0003
inch) Crankshaft maximum end play
.................................................................................................................................... 0.05 - 0.32 mm
(0.002 - 0.0126 inch)
Crankshaft Main Bearing Cap bolts
..........................................................................................................................................................
97 Nm (72 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications
Engine Block Heater: Specifications
Block Heater Screw .............................................................................................................................
.................................................... 2 Nm (18 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications > Page 2903
Engine Block Heater: Service and Repair
Block Heater
Removal and Installation
1. Drain the cooling system. 2. With the vehicle in neutral, position it on a hoist. 3. Remove the
components in the order indicated.
Part 1 Of 2
Part 2 Of 2
4. To install, reverse the removal procedure. 5. Fill and bleed the cooling system.
Item 2: Block Heater Retaining Screw Removal Note
1. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal.
Loosen the block heater retaining screw.
Item 3: Block Heater Installation Note 1. Clean and inspect the engine block mating surface before
installing the block heater. Lubricate the block heater seal and the cylinder block hole
with clean engine coolant to ease installation.
Item 1: Block Heater Power Cable Installation Note 1. Make sure the power cable is routed and
secured away from rotating or hot components or damage to the cable can occur.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 ................................................................................................................................................
.................................................. 45 Nm (33 ft. lbs.) Stage 2 ................................................................
............................................................................................................................. additional 85
degrees.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2907
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Pulley and Crankshaft Seal
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the fan shroud. 2. Remove the accessory drive belt. 3. Remove the components in the
order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2908
4. To install, reverse the removal procedure.
Item 1: Crankshaft Pulley Bolt Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2909
1. CAUTION: This bolt is torque-to-yield and cannot be reused.
Using the special tool, remove and discard the damper bolt.
Item 3: Crankshaft Pulley Removal Note
1. Using the special tool, remove the crankshaft pulley.
Item 5: Front Crankshaft Seal Removal Note
1. Using the special tool, remove the crankshaft front seal.
Item 5: Front Crankshaft Seal Installation Note
1. Using the special tool, install the crankshaft front seal.
Item 3: Crankshaft Pulley Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2910
1. Using the special tool, install the crankshaft pulley
Item 1: Crankshaft Pulley Bolt Installation Note
1. Using the special tool, tighten the bolt in two stages:
1 Stage 1: Tighten the bolt to 45 Nm (33 ft. lbs.).
2 Stage 2: Tighten the bolt and additional 85 degrees.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston diameter-coded standard
...................................................................................................................... 100.380 - 100.400 mm
(3.952 - 3.9528 inch) Piston diameter-coded 0.5
................................................................................................................................. 100.880 100.900 mm (3.971 - 3.972 inch) Piston diameter-coded 1.0
................................................................................................................................. 101.350 101.370 mm (3.990 - 3.991 inch) Piston-to-cylinder bore clearance
........................................................................................................................... 0.030 - 0.050 mm
(0.0012 - 0.002 inch) Piston pin bore diameter
.................................................................................................................................... 23.958 23.976 mm (0.943 - 0.944 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston pin diameter (red)
.......................................................................................................................................
23.994-23.997 mm (0.0002-0.0003 inch) Piston pin diameter (blue)
..................................................................................................................................... 23.997-24.000
mm (0.9447-0.9449 inch) Piston pin length
............................................................................................................................................................
72.0-72.8 mm (2.835-2.866 inch) Piston pin-to-piston fit
.................................................................................................................................................
0.01-0.016 mm (0.0004-0.0006 inch) Piston pin-to-connecting rod clearance
....................................................................................................................... 0.01-0.016 mm
(0.0004-0.0006 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston ring end gap-top
............................................................................................................................................. 0.200 0.450 mm (0.008 - 0.018 inch) Piston ring end gap- bottom
.......................................................................................................................................... 0.40 - 0.60
mm (0.015 - 0.024 inch) Piston ring groove width -top
.................................................................................................................................... 1.23 - 1.25 mm
(0.0484 - 0.0492 inch) Piston ring groove width -bottom
.............................................................................................................................. 1.52 - 1.54 mm
(0.0598 - 0.0606 inch) Piston ring groove width -oil ring
............................................................................................................................. 3.01 - 3.03 mm
(0.1185 - 0.1193 inch) Piston ring width-top
............................................................................................................................................. 1.175 1.190 mm (0.0463 - 0.0469 inch) Piston ring width -bottom
...................................................................................................................................... 1.475 - 1.490
mm (0.0581 - 0.0587 inch) Piston ring-to-groove clearance-top
.................................................................................................................. 0.040 - 0.075 mm (0.0016
- 0.0030 inch) Piston ring-to-groove clearance-bottom
................................................................................................................ 0.030 - 0.065 mm (0.0012 0.0026 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 2924
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 2925
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Camshaft Roller Follower and Hydraulic Lash Adjuster
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers. 2. Remove the components in the order indicated.
3. To install, reverse the removal procedure. 4. Install the LH and RH valve covers.
Item 1: Camshaft Roller Followers Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Page 2929
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Item 2: Hydraulic Lash Adjuster Removal Note
1. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position.
Remove the hydraulic lash adjusters.
Item 11: Camshaft Roller Followers Installation Note
1. NOTE: The roller followers must be installed in their original position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Page 2930
Using the special tool, install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Specifications
Valve Cover: Specifications
Valve Cover Bolts ................................................................................................................................
................................................. 10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH
Valve Cover: Service and Repair Valve Cover RH
Valve Cover RH
Removal and Installation
1. Release the fuel system pressure. 2. Remove the intake manifold.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH > Page 2936
Part 2 Of 2
3. Illustration 1 of 2. Remove the components in the order indicated.
4. Illustration 2 of 2. Remove the components in the order indicated. 5. To install, reverse the
removal procedure.
Item 4: Fuel Supply Manifold Spring Lock Coupling Removal Note
1. Disconnect the fuel injector electrical connectors and routing clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH > Page 2937
2. Install the special tool.
3. Press the special tool into the open end of the cage.
4. Separate the fuel line fitting.
Item 7: Fuel Supply Manifold Removal Note
1. 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.
Discard the fuel supply manifold O-ring and install a new O-ring.
Item 8: Spark Plug Wires Removal Note
1. Disconnect the retaining clips and position the spark plug wires aside.
Item 11: RH Valve Cover Gasket Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH > Page 2938
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools cause
scratches and gouges which make leak paths.
Clean and inspect the sealing surfaces. Install a new gasket, if necessary.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH > Page 2939
Valve Cover: Service and Repair Valve Cover LH
Valve Cover LH
Removal and Installation
1. Remove the intake manifold.
2. Illustration 1 of 2. Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH > Page 2940
3. Illustration 2 of 2. Remove the components in the order indicated. 4. To install, reverse the
removal procedure.
Item 2: Ignition Coil Electrical Connector Removal Note 1. Detach the pin-type retainer on the
wiring harness near the ignition coil electrical connector.
2. Disconnect the fuel injector electrical connectors and the harness standoff clips.
Item 3: Accelerator Cable Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover RH > Page 2941
1. Disconnect the accelerator cable from the routing clip and position it aside.
Item 4: Spark Plug Wires Removal Note
1. Disconnect the standoff clips and position the spark plug wires aside.
Item 7: Valve Cover Gasket Removal Note
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools cause
scratches and gouges which make leak paths.
Clean and inspect the sealing surfaces. Install a new gasket, if necessary.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH
Valve Spring: Service and Repair Camshaft, Valve Springs and Valve Seals-RH
Camshaft, Valve Springs and Valve Seals-RH
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers.
2. NOTE: This step is necessary for camshaft removal only.
Remove the cooling fan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2946
3. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2947
Part 2 Of 2
4. To install, reverse the removal procedure.
5. NOTE: This step is necessary for camshaft installation only.
Install the cooling fan.
6. Install the LH and RH valve covers.
Item 2: Camshaft Roller Follower Removal Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2948
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Items 3, 4 and 5: Valve Spring Retainer Keys, Valve Spring Retainers and Valve Springs Removal
Note 1. Position the piston of the cylinder being serviced at top dead center (TDC). 2. Hold the
valves in the cylinder head.
^ Remove the spark plug of the cylinder being serviced.
^ Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Items 7-12: Camshaft Sprocket, Main Bearing Cap Mounting Bolts, Oil Supply Tube, Main Bearing
Caps and Camshaft Removal Note
1. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is
serviced.
Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2949
3. NOTE: The special tool must be installed on the damper and should contact the engine block,
this positions the piston at TDC.
Install the special tools.
4. Install the special tools on the rear of the RH cylinder head and tighten the top two clamp bolts to
10 Nm (89 inch lbs.)
5. CAUTION: The RH camshaft sprocket is a LH threaded bolt.
Using the special tool, loosen the camshaft sprocket bolt.
6. Remove the special tools.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2950
7. Remove the bolt and position the camshaft sprocket aside.
8. 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.
Items 12-7: Camshaft, Main Bearing Caps, Oil Supply Tube, Main Bearing Cap Mounting Bolts,
and Camshaft Sprocket Installation Note
1. 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 the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
2. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2951
Install the camshaft sprocket and loosely install the bolt.
3. The camshafts must be retimed.
Item 6: Valve Seals Installation Note
1. Using the special tool, install the valve stem seal.
Item 5-3: Valve Spring, Valve Spring Retainers, and Valve Spring Retainer Keys Installation Note
1. 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, install the valve spring retainer keys, the valve springs and the retainers.
Item 2: Roller Follower Installation Note
1. NOTE: The roller followers must be installed in their original position.
Using the special tool install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2952
Valve Spring: Service and Repair Camshaft, Valve Springs and Valve Seals-LH
Camshaft, Valve Springs and Valve Seals-LH
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers.
2. NOTE: This step is necessary for camshaft removal only.
Remove the cooling fan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2953
3. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2954
Part 2 Of 2
4. To install, reverse the removal procedure.
5. NOTE: This step is necessary for camshaft installation only.
Install the cooling fan.
6. Install the LH and RH valve covers.
Item 2: Camshaft Roller Follower Removal Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2955
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Items 3, 4 and 5: Valve Spring Retainer Keys, Valve Spring Retainers and Valve Springs Removal
Note 1. Position the piston of the cylinder being serviced at Top Dead Center (TDC). 2. Hold the
valves in the cylinder head.
^ Remove the spark plug of the cylinder being serviced.
^ Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Items 7-12: Camshaft Sprocket, Main Bearing Cap Mounting Bolts, Oil Supply Tube, Main Bearing
Caps and Camshaft Removal Note
1. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is
serviced.
Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2956
3. NOTE: The special tool must be installed on the damper and should contact the engine block,
this positions the piston at TDC.
Install the special tool.
4. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to
10 Nm (89 inch lbs.).
5. Loosen the bolt.
6. Remove the special tools.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2957
7. Remove the bolt and position the camshaft sprocket aside.
8. 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.
Items 12-7: Camshaft, Main Bearing Caps, Oil Supply Tube, Main Bearing Cap Mounting Bolts,
and Camshaft Sprocket Installation Note
1. 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 the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2958
2. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time
Install the camshaft sprocket and loosely install the bolt.
3. The camshafts must be retimed.
Item 6: Valve Seals Installation Note
1. Using the special tool, install the valve stem seal.
Item 5, 4, and 3: Valve Spring, Valve Spring Retainer, Valve Spring Retainer Keys Installation Note
1. 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, install the valve spring, valve spring retainer, and the valve spring retainer
keys.
Item 2: Roller Follower Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 2959
1. NOTE: The roller followers must be installed in their original position.
Using the special tool, install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 05-17-8 > Sep > 05 > A/C
- Drive Belt Chirp When A/C Compressor Engages
Drive Belt: Customer Interest A/C - Drive Belt Chirp When A/C Compressor Engages
TSB 05-17-8
09/05/05
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a chirp
noise from the front end accessory drive (FEAD) belt when the A/C compressor is engaging.
ACTION Verify concern. Replace the A/C compressor clutch pulley, and set the clutch air gap to
the specification listed in this TSB (the Workshop Manual specification is being updated). Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Recover the refrigerant.
2. Remove the A/C compressor. Refer to Workshop Manual Section 412.
3. Using the special tool 412-098, hold the A/C clutch plate and remove the clutch nut.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C clutch hub spacer.
6. Remove the A/C compressor pulley snap ring.
CAUTION
DO NOT USE AIR TOOLS. DAMAGE TO THE A/C CLUTCH PULLEY OR A/C COMPRESSOR
MAY RESULT.
7. Using the special tool 412-001, remove the A/C clutch pulley.
8. Install the new A/C clutch pulley using special tool 412-109.
9. Reinstall the A/C compressor pulley snap ring.
10. Reinstall the original A/C clutch hub spacer.
11. Reinstall the A/C clutch disc and hub.
12. Using special tool 412-098, hold the A/C clutch plate and reinstall the A/C clutch nut. Tighten to
14 lb-ft (19 N.m).
13. Measure and adjust the clutch air gap to 0.010 - 0.024" (0.254 - 0.610 mm), by adding or
removing A/C clutch disc and hub spacers.
14. Reinstall the A/C compressor.
15. Recharge the system.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051708A 2002-2005 1.1 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 05-17-8 > Sep > 05 > A/C
- Drive Belt Chirp When A/C Compressor Engages > Page 2969
Explorer/Mountaineer 4.0L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708B 2002-2005 1.2 Hrs.
Explorer/Mountaineer 4.6L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708C 2003-2005 Aviator: 1.4 Hrs.
Replace The A/C Compressor Clutch Pulley (Do Not Use With 19700A, 19700A4, 19700AZU,
19700R)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D784 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-17-8 > Sep
> 05 > A/C - Drive Belt Chirp When A/C Compressor Engages
Drive Belt: All Technical Service Bulletins A/C - Drive Belt Chirp When A/C Compressor Engages
TSB 05-17-8
09/05/05
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a chirp
noise from the front end accessory drive (FEAD) belt when the A/C compressor is engaging.
ACTION Verify concern. Replace the A/C compressor clutch pulley, and set the clutch air gap to
the specification listed in this TSB (the Workshop Manual specification is being updated). Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Recover the refrigerant.
2. Remove the A/C compressor. Refer to Workshop Manual Section 412.
3. Using the special tool 412-098, hold the A/C clutch plate and remove the clutch nut.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C clutch hub spacer.
6. Remove the A/C compressor pulley snap ring.
CAUTION
DO NOT USE AIR TOOLS. DAMAGE TO THE A/C CLUTCH PULLEY OR A/C COMPRESSOR
MAY RESULT.
7. Using the special tool 412-001, remove the A/C clutch pulley.
8. Install the new A/C clutch pulley using special tool 412-109.
9. Reinstall the A/C compressor pulley snap ring.
10. Reinstall the original A/C clutch hub spacer.
11. Reinstall the A/C clutch disc and hub.
12. Using special tool 412-098, hold the A/C clutch plate and reinstall the A/C clutch nut. Tighten to
14 lb-ft (19 N.m).
13. Measure and adjust the clutch air gap to 0.010 - 0.024" (0.254 - 0.610 mm), by adding or
removing A/C clutch disc and hub spacers.
14. Reinstall the A/C compressor.
15. Recharge the system.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051708A 2002-2005 1.1 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-17-8 > Sep
> 05 > A/C - Drive Belt Chirp When A/C Compressor Engages > Page 2975
Explorer/Mountaineer 4.0L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708B 2002-2005 1.2 Hrs.
Explorer/Mountaineer 4.6L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708C 2003-2005 Aviator: 1.4 Hrs.
Replace The A/C Compressor Clutch Pulley (Do Not Use With 19700A, 19700A4, 19700AZU,
19700R)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D784 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Page 2976
Component Locations 4.0L
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Inspection and Verification
1. Verify the customer's concern by operating the engine to duplicate the condition.
Visual Inspection Chart
2. Inspect to determine if any of the mechanical concerns apply. 3. Inspect for drive belt
cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms. GO to
Symptom Chart. See: Symptom Related Diagnostic Procedures
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. A new drive belt should be installed if chunking occurs.
V-Ribbed Belt With Cracks (Acceptable)
V-Ribbed Serpentine Drive Belt with Cracks Across Backing
V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable)
V-Ribbed Serpentine Drive Belt with Chunks of Rib Missing
5. If the concern(s) remains after inspection, determine the symptoms. GO to Symptom Chart.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2979
Drive Belt: Symptom Related Diagnostic Procedures
Symptom Chart
Part 1 Of 2
Part 2 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 2980
Drive Belt: Component Tests and General Diagnostics
Drive Belt-Misalignment
CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the
drive bed 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 necessary.
^ Check all accessories, mounting brackets and drive belt tensioner, for any interference that would
prevent the component from mounting correctly. 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 2981
Drive Belt: Service and Repair
Accessory Drive Belt, Tensioner and Pulley
Removal and Installation
1. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Part 2 Of 2
2. To install, reverse the removal procedure.
Item 1: Accessory Drive Belt Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 2982
1. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
1 Rotate the accessory drive belt tensioner counterclockwise.
2 Remove the accessory drive belt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Specifications
Drive Belt Tensioner: Specifications
Accessory Drive Belt Tensioner Bolts
...................................................................................................................................................... 25
Nm (18 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Specifications > Page 2986
Drive Belt Tensioner: Testing and Inspection
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 be checked by installing the suspect
drive belt with a known good original equipment drive belt and repeating the observation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Specifications > Page 2987
Drive Belt Tensioner: Service and Repair
Accessory Drive Belt, Tensioner and Pulley
Removal and Installation
1. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Part 2 Of 2
2. To install, reverse the removal procedure.
Item 1: Accessory Drive Belt Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Specifications > Page 2988
1. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
1 Rotate the accessory drive belt tensioner counterclockwise.
2 Remove the accessory drive belt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
..........................................................................................................................................................
90 Nm (66 ft. lbs.) Lower Engine Mount Bracket Bolts
......................................................................................................................................................... 80
Nm (59 ft. lbs.) Upper Engine Mount Bracket Nuts
........................................................................................................................................................
110 Nm (81 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 2992
Engine Mount: Service and Repair
Engine Support Insulators
Special Tool(s)
Removal and Installation
CAUTION: Any time bolts, washers, spacers, or nuts are loosened in the differential support for any
reason, install new components to prevent damage.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the exhaust gas recirculation (EGR) valve tube.
4. Remove the upper fan shroud.
^ Remove the bolts and, if equipped, the assembly screws.
^ Discard the assembly screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 2993
5. Remove the LH radio capacitor.
6. Remove the bolt and install the lifting eye.
7. Install the special tools.
8. Remove the components in the order indicated. To remove individual components, only carry out
the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 2994
9. NOTE: These steps are necessary for 4x4 equipped vehicles only.
Illustration 1 of 3. Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 2995
10. Illustration 2 of 3. Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 2996
11. Illustration 3 of 3. Remove the components in the order indicated. 12. To install, reverse the
removal procedure.
Item 2: Stabilizer Bar Removal Note 1. Allow the stabilizer bar to hang freely to allow clearance for
motor mount removal.
Item 6: Axle Housing Removal Note
1. WARNING: Secure the axle to the jack with a safety strap. Failure to follow these instructions
can result in personal injury.
Support the axle housing with a suitable jackstand.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications > Page 2997
2. Disconnect the vent hose from the differential housing vent tube.
Items 8, 9, 11 and 12: RH and LH Motor Mount and Through Bolt Removal Note 1. Using a suitable
jack, raise the engine to remove the appropriate motor mount.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications
Idler Pulley: Specifications
Accessory Drive Belt Idler Pulley Bolt
.................................................................................................................................................... 47
Nm (35 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications > Page 3001
Idler Pulley: Service and Repair
Accessory Drive Belt, Tensioner and Pulley
Removal and Installation
1. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Part 2 Of 2
2. To install, reverse the removal procedure.
Item 1: Accessory Drive Belt Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications > Page 3002
1. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
1 Rotate the accessory drive belt tensioner counterclockwise.
2 Remove the accessory drive belt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure minimum at 2,000 rpm (engine at normal operating temperature)
........................................................................................... 103 kPa (15 psi)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 3007
Engine Oil Pressure: Testing and Inspection
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure
Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating
temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5.
The oil pressure should be within specifications. 6. If the pressure is not within specification, check
the following possible sources:
^ insufficient oil
^ oil leakage
^ worn or damaged oil pump
^ oil pump screen cover and tube
^ excessive main bearing clearance
^ excessive connecting rod bearing clearance
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Engine - Oil Level Indicator Markings
Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Oil Level Indicator
Markings
Article No. 03-8-3
04/28/03
ENGINE - ENGINE OIL LEVEL INDICATOR MARKINGS - REPORTS OF LOW OIL LEVELS
FORD: 2002 ESCORT 2002-2003 CROWN VICTORIA, ESCORT ZX2, FOCUS, MUSTANG,
TAURUS, THUNDERBIRD, E SERIES, ESCAPE, EXCURSION, EXPEDITION, EXPLORER
SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES,
WINDSTAR
LINCOLN: 2002 CONTINENTAL 2002-2003 LS, TOWN CAR, NAVIGATOR 2003 AVIATOR
MERCURY: 2002-2003 COUGAR, GRAND MARQUIS, SABLE 2002 VILLAGER 2002-2003
MOUNTAINEER
ISSUE Reports from the field indicate incorrect or low engine oil levels are being found at
Pre-Delivery Inspection on new vehicles received in dealer inventory. In most cases, the level is
being misinterpreted because the fluid fill mark on the stick is not touching the top hash mark at the
upper limit (or MAX mark), or is partway down the crosshatch area.
ACTION Ford is in the process of standardizing the markings across all vehicle lines. Current
markings shown will be upgraded to a refined marking, shown in Figure 1. Both markings will be
used in production over the next few years. Oil levels will still be recorded in the crosshatched area
of the blade, between the upper and lower limit holes. Vehicles shipped with engine oil levels falling
within this area are acceptable and do not require topping off. Oil fill quantities are precisely
measured at the plants and account for slight variations that may occur in oil pan volumes,
indicator length, and pressed-in locations of the indicator tube into the block. For customer use, the
markings continue to serve as a guide to refilling the engine to the correct initial fill volume with
filter or, to top off the engine when it is determined the level is below the lower hole.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Engine - Oil Level Indicator Markings > Page 3012
SERVICE INFORMATION
Ensure the vehicle is sitting on level ground. Set the park brake and ensure the transmission
selector lever is in PARK position, or in FIRST gear on manuals. The engine must be OFF.
The best time for determining oil level is before the engine is started and the oil has had sufficient
drainback time to the sump. If the engine has been running, allow it to sit for a few minutes turned
off. An oil drainback period is required before taking an initial reading.
If the level falls below the lower hole, fill with one quart of oil. If one quart is insufficient to raise the
level above the mark, add oil until it records within the crosshatch area. Use caution during this
procedure as some time is needed for oil to drain down through the drainback passages in the
cylinder head, to the oil pan. Adding oil a quart at a time repeatedly without sufficient drainback
may overfill the sump.
If the oil level falls between the upper and lower hole do not add more oil. Adding an extra quart
could cause overfilling and may result in aeration (foaming) causing eventual damage to vital
bearing surfaces and moving parts inside. Overfilling will require some oil to be drained out until the
indicator shows the level between the upper and lower holes of the blade. DO NOT expect the
engine to 'consume" the extra oil back down to the upper oil till level hole, or consider it as extra
lubrication protection for the engine.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 401000, 490000, 499000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Page 3013
Engine Oil Dip Stick - Dip Stick Tube: Specifications
Oil Level Indicator Tube Bracket Bolt
.................................................................................................................................................. 10 Nm
(89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 3018
Engine Oil: Fluid Type Specifications
Engine Oil ................................................................................................................ Super Premium
SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Specifications
Oil Filter: Specifications
Oil Bypass Filter ..................................................................................................................................
........................................................ 13 N (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Technical Service Bulletins > Customer Interest for Oil Filter Adapter: > 04-19-10 > Sep > 04 > Engine - Oil
Leaks From Oil Filter Adapter
Oil Filter Adapter: Customer Interest Engine - Oil Leaks From Oil Filter Adapter
TSB 04-19-10
09/22/04
OIL LEAK FROM OIL FILTER ADAPTER - 4.0L SOHC ENGINE BUILT BEFORE 4/1/2004
FORD: 2003 Explorer Sport 2003-2004 Explorer Sport Trac, Explorer, Ranger
MERCURY: 2003-2004 Mountaineer
ISSUE
Some vehicles equipped with a 4.0L SOHC engine, with an engine build date of 04/01/2004 or
earlier, may exhibit an oil leak from the rear of the engine. The leak may be coming from the oil
filter adapter, due to porosity. When the oil filter adapter leaks, the oil may wick around or follow the
ladder frame gasket channel to the rear of the engine. The oil leak may appear to be coming from
the rear main oil seal and/or ladder frame gasket area.
ACTION
Inspect the oil filter adapter and determine the oil leak source, per Workshop Manual Section
303-00, prior to any repair attempts. If the oil filter adapter is the source, replace the adapter. Refer
to the following Service Procedure.
SERVICE PROCEDURE
OIL FILTER ADAPTER REMOVAL
1. Remove the right hand exhaust manifold. Refer to Workshop Manual Section 303-01.
2. Remove the oil filter.
3. Remove the oil filter adapter mounting bolt and the adapter from the engine.
OIL FILTER ADAPTER INSTALLATION
1. Position the new oil filter adapter and gasket to the cylinder block.
2. Install a new oil filter mounting bolt seal onto the mounting bolt and install the bolt into the engine
block (hand-tighten).
3. Torque the adapter mounting bolt to 57 Nm (42 lb-ft).
4. Install new oil filter.
5. Refill oil to proper level.
6. Reinstall exhaust manifold per Workshop Manual Section 303-01.
PARTS BLOCK
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Technical Service Bulletins > Customer Interest for Oil Filter Adapter: > 04-19-10 > Sep > 04 > Engine - Oil
Leaks From Oil Filter Adapter > Page 3030
LABOR OPERATION CLAIMING CHART
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6881 D1
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter Adapter: > 04-19-10 > Sep > 04 >
Engine - Oil Leaks From Oil Filter Adapter
Oil Filter Adapter: All Technical Service Bulletins Engine - Oil Leaks From Oil Filter Adapter
TSB 04-19-10
09/22/04
OIL LEAK FROM OIL FILTER ADAPTER - 4.0L SOHC ENGINE BUILT BEFORE 4/1/2004
FORD: 2003 Explorer Sport 2003-2004 Explorer Sport Trac, Explorer, Ranger
MERCURY: 2003-2004 Mountaineer
ISSUE
Some vehicles equipped with a 4.0L SOHC engine, with an engine build date of 04/01/2004 or
earlier, may exhibit an oil leak from the rear of the engine. The leak may be coming from the oil
filter adapter, due to porosity. When the oil filter adapter leaks, the oil may wick around or follow the
ladder frame gasket channel to the rear of the engine. The oil leak may appear to be coming from
the rear main oil seal and/or ladder frame gasket area.
ACTION
Inspect the oil filter adapter and determine the oil leak source, per Workshop Manual Section
303-00, prior to any repair attempts. If the oil filter adapter is the source, replace the adapter. Refer
to the following Service Procedure.
SERVICE PROCEDURE
OIL FILTER ADAPTER REMOVAL
1. Remove the right hand exhaust manifold. Refer to Workshop Manual Section 303-01.
2. Remove the oil filter.
3. Remove the oil filter adapter mounting bolt and the adapter from the engine.
OIL FILTER ADAPTER INSTALLATION
1. Position the new oil filter adapter and gasket to the cylinder block.
2. Install a new oil filter mounting bolt seal onto the mounting bolt and install the bolt into the engine
block (hand-tighten).
3. Torque the adapter mounting bolt to 57 Nm (42 lb-ft).
4. Install new oil filter.
5. Refill oil to proper level.
6. Reinstall exhaust manifold per Workshop Manual Section 303-01.
PARTS BLOCK
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Filter Adapter: > 04-19-10 > Sep > 04 >
Engine - Oil Leaks From Oil Filter Adapter > Page 3036
LABOR OPERATION CLAIMING CHART
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6881 D1
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Technical Service Bulletins > Page 3037
Oil Filter Adapter: Specifications
Oil Filter Adapter Bolt ..........................................................................................................................
.................................................... 57 Nm (42 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Oil Pan Bolts ........................................................................................................................................
................................................... 9 Nm (80 inch lbs.) Oil Pan Drain Plug ............................................
........................................................................................................................................ 26 Nm (19 ft.
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3041
Oil Pan: Service and Repair
Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube
1. Drain the engine oil.
Part 1 Of 2
Part 2 Of 2
2. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
3. NOTE: The illustration and related steps are only intended for 4x4 vehicles only.
Illustration 1 of 2. Remove the components in the order indicated in the illustration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3042
Part 1 Of 3
Part 2 Of 3
Part 3 Of 3
4. Illustration 2 of 2. Remove the components in the order indicated in the illustration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3043
5. To install, reverse the removal procedure. 6. Fill the engine with clean engine oil.
Item 6: Axle Housing Removal Note
1. CAUTION: Do not let the axle housing hang freely. Failure to follow this instruction can result in
damage to the vehicle.
Using a transmission jack, lower the axle housing to gain clearance for the removal of the oil pan.
Item 17: Lower Block Cradle Removal Note
1. CAUTION: Failure to back off the set screws can result in damage to the lower block cradle.
Back the set screws off until they are below the lower block cradle boss.
Item 18: Lower Block Cradle Gasket Removal Note
1. NOTE: Gasket material as well as silicone sealant may be present in the cavities in the main
bearing cap. This material must be removed
completely prior to assembly.
Clean the sealant from the cavities on the rear main bearing cap.
Item 18: Lower Block Cradle Gasket Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3044
1. NOTE: If the block cradle gasket is not secured within four minutes of the sealant application, the
sealant must be removed and the sealing area
cleaned with metal surface cleaner. Allow the silicone to dry until there is no sign of wetness, or
four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone in the six places shown.
Item Number 12, 13,14,15,16 and 17: Lower Block Cradle and Bolts Installation Note
1. Position the lower block cradle and gasket assembly.
2. Install and hand-tighten the outer bolts and nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3045
3. Install and hand-tighten the rear lower block cradle bolts.
4. Install the two rear lower block cradle-to-bell housing bolts.
5. NOTE: The lower block cradle to the cylinder block alignment must be within a maximum
mismatch of 0.25 mm (0.01 inch) lower block cradle
underflush or 0.05 mm (0.00196 inch) lower block cradle protrusion.
Using a straightedge, align the transmission face of the lower block cradle with the rear face of the
cylinder block.
6. Tighten the outer bolts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3046
7. Tighten the rear lower block cradle bolts.
8. Tighten the eight inserts.
9. Install the two silver covered bolts and new washer seals. Hand-tighten them at this time.
10. Install and hand-tighten the six remaining bolts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 3047
11. Tighten the lower block cradle bolts in two stages:
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 34 Nm (25 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
View 151-35
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 3051
View 151-53
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 3052
View 151-59
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 3053
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair
Oil Pick Up/Strainer: Service and Repair
Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube
1. Drain the engine oil.
Part 1 Of 2
Part 2 Of 2
2. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
3. NOTE: The illustration and related steps are only intended for 4x4 vehicles only.
Illustration 1 of 2. Remove the components in the order indicated in the illustration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3057
Part 1 Of 3
Part 2 Of 3
Part 3 Of 3
4. Illustration 2 of 2. Remove the components in the order indicated in the illustration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3058
5. To install, reverse the removal procedure. 6. Fill the engine with clean engine oil.
Item 6: Axle Housing Removal Note
1. CAUTION: Do not let the axle housing hang freely. Failure to follow this instruction can result in
damage to the vehicle.
Using a transmission jack, lower the axle housing to gain clearance for the removal of the oil pan.
Item 17: Lower Block Cradle Removal Note
1. CAUTION: Failure to back off the set screws can result in damage to the lower block cradle.
Back the set screws off until they are below the lower block cradle boss.
Item 18: Lower Block Cradle Gasket Removal Note
1. NOTE: Gasket material as well as silicone sealant may be present in the cavities in the main
bearing cap. This material must be removed
completely prior to assembly.
Clean the sealant from the cavities on the rear main bearing cap.
Item 18: Lower Block Cradle Gasket Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3059
1. NOTE: If the block cradle gasket is not secured within four minutes of the sealant application, the
sealant must be removed and the sealing area
cleaned with metal surface cleaner. Allow the silicone to dry until there is no sign of wetness, or
four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone in the six places shown.
Item Number 12, 13,14,15,16 and 17: Lower Block Cradle and Bolts Installation Note
1. Position the lower block cradle and gasket assembly.
2. Install and hand-tighten the outer bolts and nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3060
3. Install and hand-tighten the rear lower block cradle bolts.
4. Install the two rear lower block cradle-to-bell housing bolts.
5. NOTE: The lower block cradle to the cylinder block alignment must be within a maximum
mismatch of 0.25 mm (0.01 inch) lower block cradle
underflush or 0.05 mm (0.00196 inch) lower block cradle protrusion.
Using a straightedge, align the transmission face of the lower block cradle with the rear face of the
cylinder block.
6. Tighten the outer bolts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3061
7. Tighten the rear lower block cradle bolts.
8. Tighten the eight inserts.
9. Install the two silver covered bolts and new washer seals. Hand-tighten them at this time.
10. Install and hand-tighten the six remaining bolts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 3062
11. Tighten the lower block cradle bolts in two stages:
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 34 Nm (25 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure minimum at 2,000 rpm (engine at normal operating temperature)
........................................................................................... 103 kPa (15 psi)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 3067
Engine Oil Pressure: Testing and Inspection
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure
Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating
temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5.
The oil pressure should be within specifications. 6. If the pressure is not within specification, check
the following possible sources:
^ insufficient oil
^ oil leakage
^ worn or damaged oil pump
^ oil pump screen cover and tube
^ excessive main bearing clearance
^ excessive connecting rod bearing clearance
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair
Intake Manifold: Service and Repair
Intake Manifold
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet pipe.
3. Illustration 1 of 4 Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Page 3071
4. Illustration 2 of 4 Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Page 3072
5. Illustration 3 of 4 Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Page 3073
6. Illustration 4 of 4 Remove the components in the order indicated. 7. To install, reverse the
removal procedure.
Items 1 and 2: Accelerator Cable and Speed Control Cable Removal Note
1. Disconnect the accelerator and the speed control cables from the throttle body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Page 3074
2. Remove the accelerator cable and the speed control cable from the bracket. Position the cables
away from the intake manifold.
3. Disconnect the accelerator cable and the speed control cable routing clips. Disconnect the
vacuum hose.
4. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wires.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Disconnect the spark plug wires.
5. Disconnect the Knock Sensor (KS) electrical connector retainer.
Item 21: Intake Manifold Gaskets Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Page 3075
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools can
cause scratches and gouges which can make leak paths.
Clean the sealing surfaces, inspect the gaskets and install new gaskets if necessary.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Flexplate or Flywheel and Crankshaft Rear Seal
Special Tool(s)
1. Remove the transmission.
2. To remove individual components, carry out only the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3080
3. Remove the components in the order indicated. 4. To install, reverse the removal procedure.
Item 5: Crankshaft Rear Oil Seal Removal Note
1. CAUTION: Avoid scratching or damaging the crankshaft rear oil seal running surface during
removal of the crankshaft rear oil seal.
Using the special tools, remove the crankshaft rear oil seal.
Item 5: Crankshaft Rear Oil Seal Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3081
1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To
clean the-crankshaft rear sealing surface, use
extra-fine emery cloth or extra-fine steel wool with metal surface cleaner.
Lubricate the crankshaft rear oil seal with clean engine oil and install the special tool. ^
Lubricate the crankshaft rear oil seal with motor oil before installation.
2. Using the special tool, install the crankshaft rear oil seal.
Item 1: Flexplate Bolt Installation Note
1. Install the flexplate. Tighten the bolts in two stages in the sequence shown.
^ Stage 1: Tighten the bolts to 13 Nm (10 inch lbs.).
^ Stage 2: Tighten the bolts to 71 Nm (52 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3086
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3087
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3088
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Crankshaft Front Oil Seal
Special Tool(s)
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 clean engine oil.
Using the special tools and install the crankshaft front oil seal.
2. Install the crankshaft pulley.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH
Valve Guide Seal: Service and Repair Camshaft, Valve Springs and Valve Seals-RH
Camshaft, Valve Springs and Valve Seals-RH
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers.
2. NOTE: This step is necessary for camshaft removal only.
Remove the cooling fan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3096
3. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3097
Part 2 Of 2
4. To install, reverse the removal procedure.
5. NOTE: This step is necessary for camshaft installation only.
Install the cooling fan.
6. Install the LH and RH valve covers.
Item 2: Camshaft Roller Follower Removal Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3098
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Items 3, 4 and 5: Valve Spring Retainer Keys, Valve Spring Retainers and Valve Springs Removal
Note 1. Position the piston of the cylinder being serviced at top dead center (TDC). 2. Hold the
valves in the cylinder head.
^ Remove the spark plug of the cylinder being serviced.
^ Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Items 7-12: Camshaft Sprocket, Main Bearing Cap Mounting Bolts, Oil Supply Tube, Main Bearing
Caps and Camshaft Removal Note
1. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is
serviced.
Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3099
3. NOTE: The special tool must be installed on the damper and should contact the engine block,
this positions the piston at TDC.
Install the special tools.
4. Install the special tools on the rear of the RH cylinder head and tighten the top two clamp bolts to
10 Nm (89 inch lbs.)
5. CAUTION: The RH camshaft sprocket is a LH threaded bolt.
Using the special tool, loosen the camshaft sprocket bolt.
6. Remove the special tools.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3100
7. Remove the bolt and position the camshaft sprocket aside.
8. 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.
Items 12-7: Camshaft, Main Bearing Caps, Oil Supply Tube, Main Bearing Cap Mounting Bolts,
and Camshaft Sprocket Installation Note
1. 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 the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
2. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3101
Install the camshaft sprocket and loosely install the bolt.
3. The camshafts must be retimed.
Item 6: Valve Seals Installation Note
1. Using the special tool, install the valve stem seal.
Item 5-3: Valve Spring, Valve Spring Retainers, and Valve Spring Retainer Keys Installation Note
1. 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, install the valve spring retainer keys, the valve springs and the retainers.
Item 2: Roller Follower Installation Note
1. NOTE: The roller followers must be installed in their original position.
Using the special tool install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3102
Valve Guide Seal: Service and Repair Camshaft, Valve Springs and Valve Seals-LH
Camshaft, Valve Springs and Valve Seals-LH
Part 1 Of 2
Part 2 Of 2
Special Tool(s)
Removal and Installation
1. Remove the LH and RH valve covers.
2. NOTE: This step is necessary for camshaft removal only.
Remove the cooling fan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3103
3. Remove the components in the order indicated. To remove individual components, carry out only
the listed steps.
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3104
Part 2 Of 2
4. To install, reverse the removal procedure.
5. NOTE: This step is necessary for camshaft installation only.
Install the cooling fan.
6. Install the LH and RH valve covers.
Item 2: Camshaft Roller Follower Removal Note
1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3105
2. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position.
Using the special tool, remove the camshaft roller followers.
Items 3, 4 and 5: Valve Spring Retainer Keys, Valve Spring Retainers and Valve Springs Removal
Note 1. Position the piston of the cylinder being serviced at Top Dead Center (TDC). 2. Hold the
valves in the cylinder head.
^ Remove the spark plug of the cylinder being serviced.
^ Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the
valve springs.
Items 7-12: Camshaft Sprocket, Main Bearing Cap Mounting Bolts, Oil Supply Tube, Main Bearing
Caps and Camshaft Removal Note
1. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is
serviced.
Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3106
3. NOTE: The special tool must be installed on the damper and should contact the engine block,
this positions the piston at TDC.
Install the special tool.
4. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to
10 Nm (89 inch lbs.).
5. Loosen the bolt.
6. Remove the special tools.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3107
7. Remove the bolt and position the camshaft sprocket aside.
8. 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.
Items 12-7: Camshaft, Main Bearing Caps, Oil Supply Tube, Main Bearing Cap Mounting Bolts,
and Camshaft Sprocket Installation Note
1. 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 the bolts in the sequence shown in two stages.
^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.).
^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3108
2. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this
time
Install the camshaft sprocket and loosely install the bolt.
3. The camshafts must be retimed.
Item 6: Valve Seals Installation Note
1. Using the special tool, install the valve stem seal.
Item 5, 4, and 3: Valve Spring, Valve Spring Retainer, Valve Spring Retainer Keys Installation Note
1. 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, install the valve spring, valve spring retainer, and the valve spring retainer
keys.
Item 2: Roller Follower Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Camshaft, Valve Springs and Valve Seals-RH > Page 3109
1. NOTE: The roller followers must be installed in their original position.
Using the special tool, install the roller followers.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations
Oil Pressure Sender: Locations
View 151-35
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 3114
View 151-53
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 3115
View 151-59
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 3116
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component
Information > Specifications
Balance Shaft: Specifications
Balance Shaft Bolts .............................................................................................................................
..................................................... 27 Nm (20 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain >
Component Information > Specifications
Balance Shaft Chain: Specifications
Balance Shaft Chain Guide .................................................................................................................
.................................................. 10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
..................................................... 85 Nm (63 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > Timing Drive Components - Hydraulic Chain Tensioner, RH
Timing Chain Tensioner: Service and Repair Timing Drive Components - Hydraulic Chain
Tensioner, RH
Timing Drive Components - Hydraulic Chain Tensioner, RH
Material
1. Remove the parts in the order indicated in the illustration and table. 2. To install, reverse the
removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > Timing Drive Components - Hydraulic Chain Tensioner, RH > Page 3131
Timing Chain Tensioner: Service and Repair Timing Drive Components - Hydraulic Chain
Tensioner, LH
Timing Drive Components - Hydraulic Chain Tensioner, LH
Material
1. Remove the parts in the order indicated in the illustration and table. 2. To install, reverse the
removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Engine Front Cover Bolts ....................................................................................................................
..................................................... 19 Nm (14 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3135
Timing Cover: Service and Repair
Engine Front Cover
Removal
1. Disconnect the battery ground cable. 2. Drain the cooling system. 3. Remove the crankshaft
pulley and front oil seal.
4. Remove the components in the order indicated. Illustration 1 of 3.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3136
5. Remove the components in the order indicated. Illustration 2 of 3.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3137
Part 1 Of 2
Part 2 Of 2
6. Remove the components in the order indicated. Illustration 3 of 3. 7. To install, reverse the
removal procedure. 8. Fill and bleed the cooling system. 9. Connect the battery ground cable.
Item 9: Heater Hose Removal Note
1. Remove the heater control valve bracket bolt.
Item 26: Engine Front Cover Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3138
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean sealing surfaces. These tools cause
scratches and gouges which make leak paths.
Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces.
2. Apply silicone gasket and sealant to the front cover in two places.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Cam Timing System
Overview
There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are
Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded.
The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A
intake phase shifting system will move the intake cam in the advance direction. The other two
possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally
as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The
systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At
idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and
Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module
(PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems
provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems
have the added benefit of improve torque. In addition a VCT system will eliminate the need for an
external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished
by controlling the overlap in valve opening between the intake valve opening and exhaust valve
closing. Increased vehicle reliability is achieved with the elimination of the EGR system.
Variable Cam Timing
Variable Cam Timing System
The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid,
a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of
equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1).
Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1
tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP
signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control
module) with crankshaft positioning information in 10 degree increments (Figure 130).
1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant
temperature), CMP, TP (throttle position), MAF
(Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine
speeds and closed throttle) the PCM controls camshaft position based on air and coolant
temperatures. During part and wide open throttle, camshaft position is determined by engine RPM,
load and throttle position. The VCT system will not operate until the engine is at normal operating
temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired
camshaft position. It will continually update the VCT solenoid duty cycle until desired
positioning is achieved. A difference between the desired and actual camshaft position represents
a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the
camshaft in a default position if a fault is detected.
5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear
piston motion to a rotational motion that
advances or retards the camshaft.
Hardware
Variable Cam Timing (VCT) Solenoid Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Page 3143
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the
solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100%
represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by
dithering (oscillating) the solenoid valve duty near 50%.
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The VCT unit assembly (Figure 132) 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, a pressure
differential occurs forcing the piston to move. This movement 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3150
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3151
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-R0087 OR EQUIVALENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3152
Fuel Pressure Test Port: Service and Repair
FUEL PRESSURE RELIEF VALVE
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: >
03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: >
03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page 3161
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner
Housing: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner
Housing: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page 3167
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Page 3168
Air Cleaner Housing: Service and Repair
AIR CLEANER ASSEMBLY
REMOVAL
1. Remove the splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Page 3169
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions > Page 3174
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions > Page 3175
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications > Page 3179
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Timing Marks and Indicators > System Information > Specifications
Timing Marks and Indicators: Specifications
Ignition Timing .....................................................................................................................................
................................................................ 10° BTDC
NOTE: Base timing only.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3190
Ignition Cable: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3191
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3192
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3193
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications
Spark Plug: Specifications
Spark Plug
Refer to Vehicle Emissions Control Information (VECI) decal for spark plug information.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3197
Spark Plug: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3198
Spark Plug: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3199
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3200
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3201
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3205
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of 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 at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3206
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 at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Water Pump Bolts ................................................................................................................................
................................................. 10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3210
Water Pump: Service and Repair
Water Pump - 4.0L SOHC
Removal and Installation
1. Drain the engine cooling system. 2. Remove the cooling fan. 3. Remove the accessory drive
belt. 4. Remove the components in the order indicated.
Part 1 Of 2
Part 2 Of 2
5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system.
Item 10: Coolant Pump Installation Note 1. Use metal surface cleaner and a suitable plastic or
wooden scraper to clean the sealing surfaces. 2. Install a new coolant pump gasket.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Pressure, Vacuum and Temperature Specifications
Coolant: Pressure, Vacuum and Temperature Specifications
Cooling System Pressure Test
Cooling system ....................................................................................................................................
.................................................... 138 kPa (20 psi)
Radiator Cap Pressure Test
Cap ......................................................................................................................................................
...................................... 89 - 124 kPa (13 - 18 psi)
Thermostat Opening Temperature
Starts to open ......................................................................................................................................
.......................................................... 90°C (194°F) Fully open ...........................................................
........................................................................................................................................ 105°C
(210°F)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Pressure, Vacuum and Temperature Specifications > Page 3216
Coolant: Capacity Specifications
Engine Coolant Capacity
Without Auxiliary Climate Control
..........................................................................................................................................................
16.3 qts (15.4L)
With Auxiliary Climate Control .............................................................................................................
.................................................. 18.2 qts (17.2L)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Pressure, Vacuum and Temperature Specifications > Page 3217
Coolant: Fluid Type Specifications
Engine Coolant Types
Use Motorcraft Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine
Coolant (yellow-colored).
Caution: Do not mix coolant types. Use the engine coolant type originally equipped with your
vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications
Coolant Reservoir: Specifications
Degas Bottle ........................................................................................................................................
.................................................... 9 Nm (80 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications > Page 3221
Coolant Reservoir: Service and Repair
Degas Bottle
Removal and Installation
1. Drain the cooling system until the degas bottle is empty. 2. Remove the air cleaner outlet tube
and the engine air cleaner. 3. Remove the components in the order indicated.
4. To install, reverse the removal procedure. 5. Fill and bleed the cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Specifications
Fan Blade: Specifications
Fan Blade To Fan Clutch Bolts ............................................................................................................
................................................... 7 Nm (62 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Tools and Equipment
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3233
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3234
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 3238
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications
Fan Shroud: Specifications
Radiator Fan Shroud, Upper ...............................................................................................................
..................................................... 7 Nm (62 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3242
Fan Shroud: Service and Repair
Radiator, Cooling Fan and Shroud
Special Tool(s)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If servicing the cooling fan shroud or
radiator, drain the cooling system.
3. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3243
4. Illustration 1 of 2. Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3244
5. Illustration 2 of 2. Remove the components in the order indicated.
Item 10: A/C Tube Removal Note
1. If equipped, detach the A/C tube from the retainers.
Item 11: Transmission Cooler Lines Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3245
1. NOTE: If equipped, remove the safety retainer from the connector.
Disconnect the cooler line. ^
If equipped, use the special tool to disconnect the quick coupler.
^ If equipped, loosen and remove the screw clamp from the hose.
Item 12: Radiator Fan Shroud Screw Removal Note 1. Not all vehicles will have these radiator fan
shroud screws. If vehicle is equipped with these screws, please discard them.
Item 15: Cooling Fan Removal Note
1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan.
Failure to follow these procedures can result in
damage to the vehicle.
Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan.
2. Using the special tools, remove the fan blade and the clutch assembly.
Item 19: Radiator Bracket Bolt Removal Note 1. If necessary, remove the radiator brackets.
Item 21: A/C Condenser Support Bracket Bolt Removal Note
1. If necessary, remove the condenser brackets.
Item 22: Radiator Removal Note
1. NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame
in order to separate the A/C condenser from the
radiator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3246
NOTE: RH side shown, LH side similar.
Remove the radiator up off the mounts and set it on the frame.
2. Remove the left inner air deflector from the A/C condenser.
3. Remove the right inner air deflector from the A/C condenser.
4. CAUTION: Do not allow the A/C condenser to hang freely or damage to the A/C lines could
occur.
NOTE: LH side shown, RH side similar.
Using mechanics wire, support both sides of the A/C condenser.
5. NOTE: It is not necessary to evacuate the A/C system. The A/C condenser can remain in the
vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3247
NOTE: It will be necessary to lift the A/C condenser up off the lower support. Move the A/C
condenser toward the front of the vehicle.
Remove the radiator and transmission cooler as an assembly and place it on a bench.
6. Remove the bolts and the transmission cooler.
7. Remove the splash shield pin-type retainers.
8. Disconnect the hose.
9. NOTE: RH side shown, LH side similar.
Remove the four bolts and the bracket.
Item 15: Cooling Fan Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3248
1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan.
Failure to follow these procedures can result in
damage to the vehicle.
Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan.
2. Using the special tools, remove the fan blade and the clutch assembly.
Item 9: Lower Degas Bottle Hose Installation Note 1. Secure the lower degas bottle hose in the clip
on the lower cooling fan shroud.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Description and Operation
Heater Control Valve: Description and Operation
HEATER CONTROL VALVE
The heater control valve is actuated by the heater control valve vacuum switch (manual climate
control) or the heater control valve vacuum control circuit (DATC). when the heater control valve is
closed (full vacuum), coolant flow through the heater core is shut off and A/C cooling efficiency is
increased.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Description and Operation > Page 3252
Heater Control Valve: Service and Repair
HEATER CONTROL VALVE AND HEATER HOSES
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. If removing any component
other than the heater control valve, drain the engine coolant. 3. If removing the heater control valve
only, clamp off the heater hoses at the heater control valve inlet and outlet.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Description and Operation > Page 3253
4. Remove the components in the order indicated in the illustration and table. To remove individual
components, carry out only the given steps.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3262
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3263
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3269
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3270
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3271
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Description and Operation > Auxiliary Climate Control
Heater Core: Description and Operation Auxiliary Climate Control
HEATER CORE
The auxiliary climate control system uses a rear heater core which operates in the same manner as
the front heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Description and Operation > Auxiliary Climate Control > Page 3274
Heater Core: Description and Operation Main Climate Control
HEATER CORE
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
HEATER CORE AND EVAPORATOR CORE HOUSING
The heater core and evaporator core housing directs airflow from the blower motor through the
evaporator core and heater core. All airflow from the blower motor passes through the evaporator
core. The airflow is then directed through or around the heater core by the temperature blend
door(s). Vehicles equipped with DATC use a partitioned heater core and evaporator core housing
with two electric actuator-positioned temperature blend doors. This allows for separate
temperatures to be selected for the driver and passenger sides of the passenger compartment.
Manual systems use a single electric actuator-positioned temperature blend door to direct airflow
through or around the heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Description and Operation > Page 3275
Heater Core: Testing and Inspection
Heater Core
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. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were
good and did not require replacement. If a heater
core leak is suspected, the heater core must be tested by carrying out the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking
the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core-Plugged
WARNING: The heater core inlet 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 inlet and
outlet hose to see if they are hot.
If the inlet hose is not hot: -
the heater control valve may be stuck closed.
- the thermostat is not working correctly.
If the outlet hose is not hot: the heater core may have an air pocket.
- the heater core may be restricted or plugged.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Clamp off the heater hoses.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater 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 ET-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 perform the bench test.
Heater Core - Bench Test
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Description and Operation > Page 3276
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, replace the heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary Climate Control
Heater Core: Service and Repair Auxiliary Climate Control
HEATER CORE - AUXILIARY
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Using suitable tools,
clamp-off the underbody heater hoses at the floorpan bracket.
Illustration 1 Of 3
3. Illustration 1 of 3. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3279
Illustration 2 Of 3
4. Illustration 2 of 3. Remove the components in the order indicated in illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3280
Illustration 3 Of 3
5. Illustration 3 of 3. Remove the components in the order indicated in the illustration and table.
Item 4: Line Bracket Screw Removal Note
1. The screw and line bracket are located inside the vehicle above the floorpan line bracket.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3281
Heater Core: Service and Repair Main Climate Control
Front Heater Core
HEATER CORE - FRONT
REMOVAL
NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is
removed from the vehicle.
1. Remove the heater core and evaporator core housing.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3282
Heater Core and Evaporator Core Housing
HEATER CORE AND EVAPORATOR CORE HOUSING, ASSEMBLY AND COMPONENTS
REMOVAL
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
- Lubricate the coolant hoses with plain water only if needed.
1. Recover the refrigerant. 2. 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
3. Remove the components in the order indicated in the illustration and table.
Item 5: Vacuum Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3283
1. Disconnect the vacuum line connectors in the engine compartment.
2. Detach the grommet and push the vacuum lines into the passenger compartment.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
3292
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
3293
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3299
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3300
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set
Case: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3306
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3307
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3308
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3309
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3315
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3316
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3317
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 3318
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Climate Control
Heater Hose: Service and Repair Auxiliary Climate Control
Front Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE - FRONT
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Drain the engine coolant.
3. Remove the RH running board brackets.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3321
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine coolant level.
Rear Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE - REAR
REMOVAL
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Drain the engine coolant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3322
3. Remove the spare tire.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine coolant level.
Item 12 & 11: Auxiliary Heater Line Installation Note
1. Clean and lubricate the coolant hoses with plain water only if needed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3323
Heater Hose: Service and Repair Main Climate Control
HEATER CONTROL VALVE AND HEATER HOSES
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. If removing any component
other than the heater control valve, drain the engine coolant. 3. If removing the heater control valve
only, clamp off the heater hoses at the heater control valve inlet and outlet.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Climate Control > Page 3324
4. Remove the components in the order indicated in the illustration and table. To remove individual
components, carry out only the given steps.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information >
Specifications
Radiator: Specifications
Radiator To Radiator Support Bolts
...........................................................................................................................................................
12 Nm (9 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud
Radiator: Service and Repair Radiator, Cooling Fan and Shroud
Radiator, Cooling Fan and Shroud
Special Tool(s)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If servicing the cooling fan shroud or
radiator, drain the cooling system.
3. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3330
4. Illustration 1 of 2. Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3331
5. Illustration 2 of 2. Remove the components in the order indicated.
Item 10: A/C Tube Removal Note
1. If equipped, detach the A/C tube from the retainers.
Item 11: Transmission Cooler Lines Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3332
1. NOTE: If equipped, remove the safety retainer from the connector.
Disconnect the cooler line. ^
If equipped, use the special tool to disconnect the quick coupler.
^ If equipped, loosen and remove the screw clamp from the hose.
Item 12: Radiator Fan Shroud Screw Removal Note 1. Not all vehicles will have these radiator fan
shroud screws. If vehicle is equipped with these screws, please discard them.
Item 15: Cooling Fan Removal Note
1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan.
Failure to follow these procedures can result in
damage to the vehicle.
Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan.
2. Using the special tools, remove the fan blade and the clutch assembly.
Item 19: Radiator Bracket Bolt Removal Note 1. If necessary, remove the radiator brackets.
Item 21: A/C Condenser Support Bracket Bolt Removal Note
1. If necessary, remove the condenser brackets.
Item 22: Radiator Removal Note
1. NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame
in order to separate the A/C condenser from the
radiator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3333
NOTE: RH side shown, LH side similar.
Remove the radiator up off the mounts and set it on the frame.
2. Remove the left inner air deflector from the A/C condenser.
3. Remove the right inner air deflector from the A/C condenser.
4. CAUTION: Do not allow the A/C condenser to hang freely or damage to the A/C lines could
occur.
NOTE: LH side shown, RH side similar.
Using mechanics wire, support both sides of the A/C condenser.
5. NOTE: It is not necessary to evacuate the A/C system. The A/C condenser can remain in the
vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3334
NOTE: It will be necessary to lift the A/C condenser up off the lower support. Move the A/C
condenser toward the front of the vehicle.
Remove the radiator and transmission cooler as an assembly and place it on a bench.
6. Remove the bolts and the transmission cooler.
7. Remove the splash shield pin-type retainers.
8. Disconnect the hose.
9. NOTE: RH side shown, LH side similar.
Remove the four bolts and the bracket.
Item 15: Cooling Fan Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3335
1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan.
Failure to follow these procedures can result in
damage to the vehicle.
Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan.
2. Using the special tools, remove the fan blade and the clutch assembly.
Item 9: Lower Degas Bottle Hose Installation Note 1. Secure the lower degas bottle hose in the clip
on the lower cooling fan shroud.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3336
Radiator: Service and Repair Cooling Module
Cooling Module
1. Drain the cooling system. 2. Recover the A/C refrigerant. 3. Remove the cooling fan. 4. Remove
the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Radiator, Cooling Fan and Shroud > Page 3337
5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. 7. Evacuate, leak
check and charge the A/C system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 3343
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 3344
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
3348
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat Opening Temperature
Starts to open ......................................................................................................................................
.......................................................... 90°C (194°F) Fully open ...........................................................
........................................................................................................................................ 105°C
(210°F)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3352
Thermostat: Service and Repair
Thermostat and Thermostat Housing - 4.0L SOHC
Removal and Installation
1. Drain the engine cooling system.
2. Remove the components in the order indicated. To remove individual components, only carry out
the listed steps.
Part 1 Of 3
Part 2 Of 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3353
Part 3 Of 3
3. To install, reverse the removal procedure. 4. Fill and bleed the cooling system.
Item 10: Thermostat Housing Installation Note 1. Inspect the thermostat housing gasket for
damage. Install a new gasket as necessary.
Item 4: Thermostat Housing Cover Installation Note 1. Inspect the thermostat housing cover gasket
for damage. Install a new gasket as necessary.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Specifications
Thermostat Housing: Specifications
Thermostat Housing Bolts (4.0L)
..........................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Water Pump Bolts ................................................................................................................................
................................................. 10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3360
Water Pump: Service and Repair
Water Pump - 4.0L SOHC
Removal and Installation
1. Drain the engine cooling system. 2. Remove the cooling fan. 3. Remove the accessory drive
belt. 4. Remove the components in the order indicated.
Part 1 Of 2
Part 2 Of 2
5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system.
Item 10: Coolant Pump Installation Note 1. Use metal surface cleaner and a suitable plastic or
wooden scraper to clean the sealing surfaces. 2. Install a new coolant pump gasket.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation
Catalytic Converter: Description and Operation
Catalyst and Exhaust Systems
The Catalytic Converter and Exhaust systems work together to control the release of harmful
engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen
(N), carbon dioxide (CO 2) and water vapor (H2O). However, it also contains carbon monoxide
(CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). CO,
NOx, 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, front heated
oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications, more than one catalyst will be used between the front and rear exhaust pipes.
Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD) system strategy in
the PCM. Refer to the Catalyst Efficiency Monitor-Federal Test Procedure at the beginning of
Section 1 for specific OBD catalyst monitor information.
The number of HO2S(s) used in the exhaust stream and the location of these sensors depend on
the vehicle emission certification level (i.e. LEV, ULEV, PZEV). Refer to (Figure 136) and (Figure
137) for typical HO2S stream locations and naming convention. On most vehicles only two HO2S
are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst will be
used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) will be utilized to
monitor catalyst efficiency. However, some Partial Zero Emission Vehicles (PZEV) will utilize three
HO2S sensors for each engine bank. The stream 1 sensors (HO2S11/HO2S21) before the catalyst
will be used for primary fuel control, the next group of sensors or stream 2 (HO2S12/HO2S22) is
utilized to monitor the light-off catalyst and the last group of sensors or stream 3
(HO2S13/HO2S23) is utilized for long term fuel trim control to optimize catalyst efficiency (Fore Aft
Oxygen Sensor Control). Currently Ford's PZEV vehicles use only a 4-cylinder engine, so only the
Bank 1 HO2S(s) will be utilized.
V-Engines
In-Line Engines
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3365
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
ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust
gases come in contact with the catalyst, they are changed into mostly harmless products. The
catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components
so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency
exceeds 50% is called catalyst light off. For most catalysts this point occurs at 475 to 575°F (246 to
301°C). A fast light catalyst is a three way catalyst (TWC) that is located as close to the exhaust
manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will
light off faster and reduce emissions quicker than the catalyst located under the body. Once the
catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that
catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high
conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly
controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly
decrease the conversion efficiency (Figure 138). For example a rich mixture will decrease the HC
and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency.
TWC Conversion Efficiency Chart
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. 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 (NOx) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter through
another HO2S mounted in the rear exhaust pipe (Figure 139) and then on into the muffler. Lastly,
the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
Note on some Partial Zero Emission Vehicles (PZEV), there will be a total of 3 HO2S in the
exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off
catalyst (stream 2) and the third (stream 3) is mounted after the light-off catalyst (Figure 140).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3366
Bank 1 Catalyst Two HO2S Configuration
Bank 1 Catalyst Three HO2S Configuration
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in-line
with the light off catalyst, or the underbody catalyst may be common to two light off catalysts,
forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system for
a specific vehicle, refer to the Exhaust System.
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 NOx. 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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3367
the engine configuration and number of cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Heated Oxygen Sensors (HO2S)
The HO2S provide the powertrain control module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how
the HO2S operates.)
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3368
Catalytic Converter: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Nuts .........................................................................................................................
.................................................... 22 Nm (16 ft. lbs.) Exhaust Manifold To Exhaust Pipe Bolts
................................................................................................................................................. 40 Nm
(30 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold LH
Exhaust Manifold: Service and Repair Exhaust Manifold LH
Exhaust Manifold LH
Removal and Installation
1. Remove the components in the order indicated. 2. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold LH > Page 3374
Exhaust Manifold: Service and Repair Exhaust Manifold RH
Exhaust Manifold RH
Removal and Installation
1. Remove the Exhaust Gas Recirculation (EGR) tube. 2. Remove the components in the order
indicated.
3. To install, reverse the removal procedure. 4. Install the EGR tube.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Specifications
Heat Shield: Specifications
Heat Shield-To-Transmission Crossmember Bolts
................................................................................................................................... 20 Nm (15 ft.
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Specifications
Muffler: Specifications
Muffler-To-Converter Bolts And Flag Nuts
............................................................................................................................................. 40 Nm
(30 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Central Security
Module
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Central Security
Module > Page 3388
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Information and Instructions
Body Control Module: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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Information and Instructions > Page 3396
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Information and Instructions > Page 3397
Symbols Part 2
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Information and Instructions > Page 3398
Symbols Part 3
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Information and Instructions > Page 3399
Symbols Part 4
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Information and Instructions > Page 3400
Symbols Part 5
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Systems Overview
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Body Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Information and Instructions > Page 3405
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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Information and Instructions > Page 3407
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Body Control Module: Connector Views
Central Security Module
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Driver Seat Module
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Body Control Module: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
59-1
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59-2
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation
Electronic Throttle Control Module: Description and Operation
Torque Based Electronic Throttle Control (ETC)
Overview
Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output
shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen
II electronic throttle body (replaces throttle cable).
Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by
not coupling the throttle angle to pedal position, which enables various fuel economy schemes and
technologies.
Background "Why Torque Based ETC"
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM
and low manifold vacuum) while still delivering the same torque requested by the driver. It should
be noted that the ETC system includes a wrench light on the instrument cluster that illuminates
when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon"
light.
It also enables many fuel economy/emission improvement technologies such as:
- VCT (deliver same torque during transitions)
- Continuously varying Transmission (CVT)
- Hybrid Electric Vehicle (HEV)
Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other generic benefits of ETC are:
- Eliminate cruise control actuators
- Eliminate ISC Bypass actuator
- Better airflow range
- Packaging (no cable)
Electronic Throttle Body
The Gen II electronic throttle body (Figure 148) has the following characteristics
1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the
throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has
the motor under the bore parallel to the plate shaft. The motor housing is
integrated into the main housing (in general this is more difficult to package). The in-series design
has a separate motor housing that protrudes out and offers more packaging flexibility.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle with no
power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default
angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from
hard-stop angle).
4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75
degree). This hard stop is non-adjustable and is set
to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use
plate sealant. The hole in the plate is not required
with ETB because the required idle airflow is provided by the plate angle, which also is the reason
there is no IAC.
6. The system has two throttle position sensors. Redundant throttle position signals are required for
monitor reasons. TP1 has a negative slope
(increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing
voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control
strategy as the indication of throttle position. The TP assembly requires four wires.
- 5 V Reference Voltage
- Signal Return (ground)
- TP1 voltage with negative voltage slope (5-0)
- TP2 voltage with positive voltage slope (0-5)
Accelerator Pedal Position Sensors (APPS)
The ETC strategy uses pedal position sensors as an input to determine the driver demand.
1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative
slope (increasing angle, decreasing voltage) and
APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal
operation APP1 is used as the indication of pedal
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position by the strategy.
2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires
and pins) between the PCM and APPS assembly.
- 2- (5 V Reference Voltage)
- 2- (Signal Return "ground")
- APP1 voltage with negative voltage slope (5-0)
- APP2 voltage with positive voltage slope (0-5)
- APP3 voltage with positive voltage slope (0-5)
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault.
The PCM knows if a signal is wrong by
calculating where it should be, inferred by the other signals. A safe value will be substituted for a
faulty signal if two out of the three signals are bad.
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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3427
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Bulletins > Customer Interest: > 03-13-6 > Jul > 03 > Engine Controls - No Start Condition
Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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Drops to Empty/MIL ON/DTC's > Page 3447
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Drops to Empty/MIL ON/DTC's > Page 3449
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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Drops to Empty/MIL ON/DTC's > Page 3450
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Drops to Empty/MIL ON/DTC's > Page 3451
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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Drops to Empty/MIL ON/DTC's > Page 3452
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General
PCM Programming Procedures
Engine Control Module: All 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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PCM Programming Procedures > Page 3457
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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PCM Programming Procedures > Page 3458
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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Bulletins > All Technical Service Bulletins for Engine Control Module: > 03-13-6 > Jul > 03 > Engine Controls - No Start
Condition
Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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Condition > Page 3463
d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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Condition > Page 3464
^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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Condition > Page 3465
^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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Condition > Page 3466
^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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Condition > Page 3467
^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM
Programming Procedures
Engine Control Module: All 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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Programming Procedures > Page 3473
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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Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM
Programming Procedures > Page 3474
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 > Relays and Modules - Powertrain Management > Relays and
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Bulletins > Page 3475
Engine Control Module: Locations
View 151-7
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View 151-17
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Views
Engine Control Module: Connector Views
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Views > Page 3480
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Flash Electrically Eraseable Programmable Read Only Memory
Engine 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 described under Programming the VID
Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635,
P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be
tailored to accommodate various hardware/parameter 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 is one of the main causes for code: P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the 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
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/or incapable of
communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and
execute Module/Parameter reprogramming referring to the manufacturers users manual. Important,
make certain that all parameters are included. Failure to properly program Tire Size in revolutions
per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or
Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be
instructed to contact the "AS BUILT" data center for the information needed to manually update the
VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is
corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician
Society (PTS) web sight 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
accomodate 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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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Flash Electrically Eraseable Programmable Read Only Memory > Page 3485
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
2. Disconnect the battery ground cable.
3. Remove the glovebox door assembly.
1 Open the glovebox door.
2 Push in on the sides of the glovebox door to release the retainers.
3 Remove the screws.
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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Flash Electrically Eraseable Programmable Read Only Memory > Page 3486
4. Remove the components in the order listed in the illustration and table.
Item 4: Powertrain Control Module (PCM) Removal Note
1. Remove the PCM and bracket as an assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Powertrain Control Module (PCM) Installation Note
1. Install the PCM and bracket as an assembly.
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Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3490
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3491
Main Relay (Computer/Fuel System): Testing and Inspection
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Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3492
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3497
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3498
Fuel Pump Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3499
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3503
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3504
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 3505
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3510
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-14
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3516
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3517
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3518
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Diagrams
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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 > Locations
Camshaft Position Sensor: Locations
View 151-73
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
3525
View 151-78
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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 > Locations > Page
3526
Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
3527
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
3528
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations
View 151-73
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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 > Locations > Page 3532
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 3533
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
View 151-8
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
3537
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
3538
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
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3539
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
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3543
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions
Fuel Tank Pressure Sensor: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions
> Page 3547
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
View 151-55
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3552
Knock Sensor: Diagrams
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3553
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
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 > Oxygen Sensor > Component Information > Locations > Oxygen Sensor
Bank Locations
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor
Bank Locations > Page 3558
Oxygen Sensor: Locations Exhaust System Oxygen Sensor Locations
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Oxygen Sensor: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3562
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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and Instructions > Page 3563
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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and Instructions > Page 3564
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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and Instructions > Page 3566
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3567
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3568
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3569
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3570
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3571
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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and Instructions > Page 3572
Oxygen Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3573
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3574
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3575
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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and Instructions > Page 3576
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3577
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3578
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3579
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3580
Oxygen Sensor: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3581
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3582
Oxygen Sensor: Application and ID
Part 1 Of 2
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3583
Part 2 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3584
Oxygen Sensor: Service and Repair
HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. With the vehicle in neutral, position it on a hoist.
2. For the RH side catalytic converter, remove the two bolts and position the heat shield aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 2: Catalyst Monitor Removal Note
1. Using the special tool, remove the catalyst monitor sensors.
Item 3: Heated Oxygen Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3586
1. Using the special tool, remove the heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
Item 3: Heated Oxygen Sensor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensors.
Item 2: Catalyst Monitor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3587
Socket, Exhaust Gas Oxygen Sensor
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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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Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3592
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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Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3593
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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Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3594
Disclaimer
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Technical Service Bulletins > Page 3595
Pressure Feedback Exhaust Sensor: Locations
View 151-75
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Technical Service Bulletins > Page 3596
View 151-76
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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 3597
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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 3598
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Technical Service Bulletins > Page 3599
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3603
View 151-76
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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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Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Locations
View 151-6
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Locations > Page 3610
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 3611
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
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Locations > Page 3612
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
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Locations > Page 3613
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
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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 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3619
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3620
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3621
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3622
Pressure Feedback Exhaust Sensor: Locations
View 151-75
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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 > Page 3623
View 151-76
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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 > Page 3624
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3625
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
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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 > Page 3626
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-14
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3631
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3632
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3633
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
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 - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
View 151-20
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3637
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and
Operation > Gasoline Fuel System
Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System
The Inertia Fuel Shutoff (IFS) switch (Figure 73) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and
Operation > Gasoline Fuel System > Page 3640
Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System
NATURAL GAS FUEL SYSTEM
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves.
The purpose of the IFS switch is to close the fuel shut-off valves if a crash 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 closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset
before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner
Guide for the location of the IFS.
Reset Instructions
1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak
is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner
Guide).
NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch)
against a spring.
4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking
natural gas.
WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO
NOT RESET THE IFS SWITCH.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and
Operation > Page 3641
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
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 - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
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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 3645
View 151-76
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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 3646
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3647
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3648
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
View 151-73
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3653
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3654
Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3655
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3656
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
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 - Ignition System > Crankshaft Position Sensor > Component Information > Locations
View 151-8
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3660
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3661
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3662
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
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Switches - Ignition System > Ignition Switch > Component Information > Locations
View 151-25
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Connector Views
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3668
Ignition Switch: Testing and Inspection
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3669
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3670
Ignition Switch: Service and Repair
IGNITION LOCK CYLINDER
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Ignition Lock Cylinder Removal Note
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the cylinder.
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 - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
View 151-55
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3674
View 151-77
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3675
Knock Sensor: Diagrams
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3676
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 3683
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 3684
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-R0087 OR EQUIVALENT.
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 3685
Fuel Pressure Test Port: Service and Repair
FUEL PRESSURE RELIEF VALVE
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 >
A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 >
A/C - Underhood - Buzz or Flutter Noise > Page 3694
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 >
Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 >
Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page 3700
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Page 3701
Air Cleaner Housing: Service and Repair
AIR CLEANER ASSEMBLY
REMOVAL
1. Remove the splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Page 3702
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 3707
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 3708
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications > Page 3712
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing
Marks and Indicators > System Information > Specifications
Timing Marks and Indicators: Specifications
Ignition Timing .....................................................................................................................................
................................................................ 10° BTDC
NOTE: Base timing only.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 3723
Ignition Cable: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 3724
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 3725
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 3726
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications
Spark Plug: Specifications
Spark Plug
Refer to Vehicle Emissions Control Information (VECI) decal for spark plug information.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3730
Spark Plug: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3731
Spark Plug: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3732
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3733
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 3734
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
The indicated compression pressures are considered within specification if the lowest reading
cylinder is at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 3738
Compression Check: Testing and Inspection
Compression Test-Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of 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 at least 75 percent of the highest reading. Refer to the Compression Pressure Limit
Chart.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty. 2. If compression does not
improve, valves are sticking or seating incorrectly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 3739
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 at least 75 percent of the highest reading.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 3744
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 3745
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 3746
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Central Security Module
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Central Security Module > Page 3751
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3754
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3755
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3756
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3757
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3758
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3759
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3760
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3761
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3762
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3763
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3764
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3765
Body Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3766
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3767
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3768
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3769
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3770
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3771
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3772
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3773
Body Control Module: Connector Views
Central Security Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3774
Driver Seat Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3775
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3776
Body Control Module: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
59-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3777
59-2
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure
Switch > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations
Camshaft Position Sensor: Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3785
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3786
Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3787
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Page 3788
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Computers and Control Circuit
Diode > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 3795
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 3796
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
View 151-8
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 3800
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 3801
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 3802
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
View 151-26
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3808
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3809
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3810
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3811
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3812
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3813
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3814
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3815
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3816
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3817
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3818
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3819
Data Link Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3820
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3821
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3822
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3823
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3824
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3825
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3826
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3827
Data Link Connector: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3828
14-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3829
Data Link Connector: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
14-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3830
14-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3831
14-3
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation
Electronic Throttle Control Module: Description and Operation
Torque Based Electronic Throttle Control (ETC)
Overview
Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output
shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen
II electronic throttle body (replaces throttle cable).
Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by
not coupling the throttle angle to pedal position, which enables various fuel economy schemes and
technologies.
Background "Why Torque Based ETC"
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM
and low manifold vacuum) while still delivering the same torque requested by the driver. It should
be noted that the ETC system includes a wrench light on the instrument cluster that illuminates
when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon"
light.
It also enables many fuel economy/emission improvement technologies such as:
- VCT (deliver same torque during transitions)
- Continuously varying Transmission (CVT)
- Hybrid Electric Vehicle (HEV)
Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other generic benefits of ETC are:
- Eliminate cruise control actuators
- Eliminate ISC Bypass actuator
- Better airflow range
- Packaging (no cable)
Electronic Throttle Body
The Gen II electronic throttle body (Figure 148) has the following characteristics
1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the
throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has
the motor under the bore parallel to the plate shaft. The motor housing is
integrated into the main housing (in general this is more difficult to package). The in-series design
has a separate motor housing that protrudes out and offers more packaging flexibility.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle with no
power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default
angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from
hard-stop angle).
4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75
degree). This hard stop is non-adjustable and is set
to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use
plate sealant. The hole in the plate is not required
with ETB because the required idle airflow is provided by the plate angle, which also is the reason
there is no IAC.
6. The system has two throttle position sensors. Redundant throttle position signals are required for
monitor reasons. TP1 has a negative slope
(increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing
voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control
strategy as the indication of throttle position. The TP assembly requires four wires.
- 5 V Reference Voltage
- Signal Return (ground)
- TP1 voltage with negative voltage slope (5-0)
- TP2 voltage with positive voltage slope (0-5)
Accelerator Pedal Position Sensors (APPS)
The ETC strategy uses pedal position sensors as an input to determine the driver demand.
1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative
slope (increasing angle, decreasing voltage) and
APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal
operation APP1 is used as the indication of pedal
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 3835
position by the strategy.
2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires
and pins) between the PCM and APPS assembly.
- 2- (5 V Reference Voltage)
- 2- (Signal Return "ground")
- APP1 voltage with negative voltage slope (5-0)
- APP2 voltage with positive voltage slope (0-5)
- APP3 voltage with positive voltage slope (0-5)
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault.
The PCM knows if a signal is wrong by
calculating where it should be, inferred by the other signals. A safe value will be substituted for a
faulty signal if two out of the three signals are bad.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 3844
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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Gauge Drops to Empty/MIL ON/DTC's > Page 3845
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 3846
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Gauge Drops to Empty/MIL ON/DTC's > Page 3848
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 3849
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 03-13-6 > Jul > 03 > Engine Controls - No
Start Condition
Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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Start Condition > Page 3857
^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 06-2-12
> Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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> Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 3868
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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> Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 3869
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
Engine Control Module: All 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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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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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 > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 03-13-6
> Jul > 03 > Engine Controls - No Start Condition
Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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> Jul > 03 > Engine Controls - No Start Condition > Page 3881
^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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> Jul > 03 > Engine Controls - No Start Condition > Page 3882
^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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> Jul > 03 > Engine Controls - No Start Condition > Page 3883
^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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> Jul > 03 > Engine Controls - No Start Condition > Page 3884
^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Dec > 04 > Engine Controls - General PCM Programming Procedures
Engine Control Module: All 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 >
Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3890
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 >
Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3891
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 > Engine Control Module >
Component Information > Technical Service Bulletins > Page 3892
Engine Control Module: Locations
View 151-7
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 3893
View 151-17
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views
Engine Control Module: Connector Views
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Component Information > Diagrams > Connector Views > Page 3896
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Component Information > Diagrams > Connector Views > Page 3897
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Component Information > Diagrams > Connector Views > Page 3898
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Connector Views > Page 3899
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory
Engine 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 described under Programming the VID
Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635,
P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be
tailored to accommodate various hardware/parameter 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 is one of the main causes for code: P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the 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
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/or incapable of
communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and
execute Module/Parameter reprogramming referring to the manufacturers users manual. Important,
make certain that all parameters are included. Failure to properly program Tire Size in revolutions
per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or
Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be
instructed to contact the "AS BUILT" data center for the information needed to manually update the
VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is
corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician
Society (PTS) web sight 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
accomodate 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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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page
3902
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
2. Disconnect the battery ground cable.
3. Remove the glovebox door assembly.
1 Open the glovebox door.
2 Push in on the sides of the glovebox door to release the retainers.
3 Remove the screws.
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3903
4. Remove the components in the order listed in the illustration and table.
Item 4: Powertrain Control Module (PCM) Removal Note
1. Remove the PCM and bracket as an assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Powertrain Control Module (PCM) Installation Note
1. Install the PCM and bracket as an assembly.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations
View 151-78
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 3907
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Service Precautions
Fuel Tank Pressure Sensor: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Service Precautions > Page 3911
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3915
Idle Speed/Throttle Actuator - Electronic: 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 122) and (Figure 123) controls engine idle speed
and provides a dash pot 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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Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 124) 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
are 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 dash pot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
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Idle Speed/Throttle Actuator - Electronic: Service and Repair
IDLE AIR CONTROL (IAC) VALVE
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Specifications
Torque Specifications
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Specifications > Page 3921
Information Bus: Locations
Module Component Location Index - Standard Corporate Protocol (SCP) Network
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Specifications > Page 3922
Module Component Location Index - International Standards Organization (ISO) Network
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Specifications > Page 3923
Module Component Location Index - Universal Asynchronous Receiver-Transmitter - (UART)
Based Protocol (UBP) Network
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Information > Diagrams > Diagram Information and Instructions > Page 3926
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Information > Diagrams > Diagram Information and Instructions > Page 3927
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Information > Diagrams > Diagram Information and Instructions > Page 3928
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Information > Diagrams > Diagram Information and Instructions > Page 3929
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Information > Diagrams > Diagram Information and Instructions > Page 3930
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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Information > Diagrams > Diagram Information and Instructions > Page 3931
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Information > Diagrams > Diagram Information and Instructions > Page 3932
Symbols Part 2
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Information > Diagrams > Diagram Information and Instructions > Page 3933
Symbols Part 3
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3934
Symbols Part 4
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3935
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3936
Systems Overview
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3937
Information Bus: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3938
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3939
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3940
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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Information > Diagrams > Diagram Information and Instructions > Page 3941
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3942
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3943
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3944
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 3945
Information Bus: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
14-1
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14-2
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14-3
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Page 3948
Information Bus: Service Precautions
CAUTION:
- Prior to removal of the DSM, it is necessary to upload module configuration information to a
diagnostic tool. This information needs to be downloaded into the new module once installed. Refer
to Module Configuration.
- Prior to removal of the vehicle security module, it is necessary to upload module configuration
information to a diagnostic tool. This information needs to be downloaded into the new module
once installed. Refer to Module Configuration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > Module Configuration
Information Bus: Description and Operation Module Configuration
Description and Operation
MODULE CONFIGURATION
Some modules must be programmed as part of the repair procedure. If this procedure is not
followed the module will not function correctly and may set a number of DTCs, including B2477 or
P1639, which indicate that some necessary data has not been programmed into the module.
Modules that need programming should not be exchanged between vehicles. In most cases the
parameter values or settings are unique to that vehicle, and if not set correctly will cause concerns
or faults.
Some programmable parameters, such as belt minder on/off, can be changed from the factory
setting at the customer's request.
Worldwide Diagnostic System (WDS) will automatically attempt to retrieve the module configuration
information from all modules. If the module cannot communicate, the diagnostic tool will either
request As-Built data or display a list of items that will need to be manually configured. The WDS
will program the module based on the data entered.
There are three different methods that are used for module programming:
- programmable module installation (PMI)
- calibration update
- programmable parameters
Some modules do not support all three methods.
Programmable Module Installation (PMI)
The programmable module installation (PMI) method is used when a new programmable module is
installed on the vehicle. It is no longer necessary to command the WDS to gather module option
content from the old module. The WDS automatically obtains any available module option content
information from the old module during the vehicle ID routine that runs when the diagnostic tool is
initially connected to the vehicle. It is important that you connect WDS to the vehicle and allow it to
identify the vehicle and obtain configuration data prior to removing any modules.
Programmable Parameters
Programmable Parameters Index
This method is used to configure parameters that can be modified in service. These are typically at
the preference of the customer. Not all features controlled by the module are listed in this
configuration method. Refer to the Module Configuration Index for a list of features by system.
If a module that has been modified using programmable parameters needs to be installed, the PMI
procedure will maintain the parameters in their altered state if WDS is able to communicate with the
old module during vehicle ID. Otherwise, programmable parameters may be needed to return them
to the altered state.
Vehicle Identification (VID) Block
Some PCMs contain a memory area called a vehicle identification (VID) block. The VID block is
used to store powertrain configuration information.
As-Built Data Center
The As-Built Data Center maintains a record of the vehicle configuration in a database. The vehicle
VIN is required to obtain this information. The
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Information > Description and Operation > Module Configuration > Page 3951
As-Built Data Center records the applicable module configurations stored in each module before
the vehicle leaves the factory. The As-Built Data Center will always reflect the original build of the
vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the
WDS.
Calibration Update
Calibration update is used to install a new calibration and strategy into a module. The updates are
usually issued to fix a concern in the module software and would normally be addressed by a
technical service bulletin (TSB). This method has been used by the PCM for several years. Other
modules will be adopting this strategy as well.
Configurable Modules
CONFIGURABLE MODULES
The vehicle contains the following modules that are configurable:
- tire pressure module
- driver seat module (DSM)
- electronic air temperature control (EATC) module
- vehicle security module
- anti-lock brake system (ABS) module
- instrument cluster
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > Module Configuration > Page 3952
Information Bus: Description and Operation Communications Network
Description and Operation
COMMUNICATIONS NETWORK
Powertrain Control Module (PCM)
The PCM is on the SCP communication network. The PCM controls the engine for better fuel
economy, emissions control, failure mode detection and storage. refer to Symptom Charts for
diagnosis and testing of the PCM.
4-wheel Anti-Lock Brake (4WABS) Control Module
The 4WABS is on the SCP communication network. The 4WABS control module controls the brake
pressure to the four wheels to keep the vehicle under control while braking.
Restraint Control Module (RCM)
The RCM is on the ISO 9141 network. The RCM controls the deployment of the air bags based on
sensor input.
Electronic Automatic Temperature Control (EATC) Module
The EATC module is on the SCP communication network. The EATC module controls automatic
climate functions that maintain the vehicle interior temperature at a constant setting.
Instrument Cluster
The instrument cluster is on the SCP communication network. The instrument cluster is also called
a hybrid electronic cluster (HEC). It is an analog face cluster with a digital odometer. The
instrument cluster displays a variety of information.
Tire Pressure Monitor Module
The tire pressure monitor module is on the SCP communication network. The tire pressure monitor
module uses one sensor mounted in each tire to sense low tire pressure. When low tire pressure is
sensed the module will send a warning to the driver.
Driver Seat Module (DSM)
The DSM is on the UBP communication network. The DSM controls the positioning and
programming of the driver seat, pedals and both outside mirrors.
Vehicle Security Module
The vehicle security module is on the UBP communication network. The vehicle security module
controls the keyless entry functions for the vehicle.
Parking Aid Module
The parking aid module is connected to the ISO 9141 communication module. The module controls
sensors in the rear bumper that detect close objects when the vehicle is in reverse.
4-Wheel Drive (4WD) Control Module
The 4WD control module is on the UBP communications network. The 4WD control module
engages and disengages the transfer case between 2WD and 4WD when more traction is required.
Principles of Operation (How Does It Work?)
PRINCIPLES OF OPERATION
The vehicle has three module communication networks: the standard corporate protocol (SCP),
which is an unshielded twisted pair cable (data bus plus, [Circuit 914 (TN/OG)] and data bus minus,
[Circuit 915 (PK/LB)], the universal asynchronous receiver transmitter (UART) based protocol
(UBP) (Circuit 693 [OG]) communications network and the international standards organization
(ISO) 9141 communications network, which is a single wire network (Circuit 70 [LB/WH]). All three
networks are connected to the data link connector (DLC). This makes diagnosis and testing of
these systems easier by allowing one smart tester to be able to diagnose and control any module
on the three networks from one connector. The DLC can be found under the instrument panel
between the steering column and the radio.
The SCP communications network 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 voltage, or
if some but not all termination resistors are lost.
The ISO 9141 communications network does not permit intermodule communication. When the
diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic
tool must ask for all information; the modules cannot initiate communications.
The ISO 9141 communications network will not function if the wire is shorted to ground or battery
voltage. Also, if one of the modules on the ISO 9141 communications network loses power or
shorts internally, communications to that module will fail.
Under normal operation the powertrain control module (PCM) communicates with the diagnostic
tool through the SCP communications network circuits
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > Module Configuration > Page 3953
914 (TN/OG) and 915 (PK/LB). If one of the bus wires becomes shorted to ground or voltage, or if
some but not all termination resistors are lost, communications can continue. Check circuits 914
(TN/OG) and 915 (PK/LB) between the PCM C175 and the DLC C251. Total resistance values
must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in circuit 914
(TN/OG) or 915 (PK/LB), damage to the DLC C251, damage to the PCM C175, or a problem in the
in-line connector C1026.
The UBP communications network will not function if the wire is shorted to ground or voltage. The
UBP is different from the ISO communication network in that it allows intermodule communication.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > Module Configuration > Page 3954
Information Bus: Description and Operation Module Controlled Functions
Description and Operation
MODULE CONTROLLED FUNCTIONS
The multifunction electronic control modules consist of the following:
- vehicle security module
- driver seat module (DSM)
Principles of Operation (How Does It Work?)
PRINCIPLES OF OPERATION
The vehicle security module controls the remote keyless entry system and computer-operated lock
system.
The driver seat module (DSM) allows automatic positioning of the memory driver seat, both outside
memory mirrors and the memory pedals to three programmable positions.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions
Information Bus: Diagnostic Trouble Code Descriptions
DTC Chart B1201 - B1318
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3957
DTC Chart B1318 - B1342
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3958
DTC Chart B1342 - B1504
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3959
DTC Chart B1505 - B1719
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3960
DTC Chart B1723 - B1952
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3961
DTC Chart B1954 - B2276
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3962
DTC Chart B2290 - B2438
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3963
DTC Chart B2439 - B2669
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3964
DTC Chart B2675 - C1155
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3965
DTC Chart C1165 - C1703
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3966
DTC Chart C1704 - C1981
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3967
DTC Chart C1991 - P1836
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3968
DTC Chart P1837 - U1073
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3969
DTC Chart U1123 - U2362
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
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Information Bus: Component Tests and General Diagnostics
Initial Inspection
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
VISUAL INSPECTION CHART
Electrical Central junction box (CJB) fuse 24 (15A)
- Wiring harness
- Connections
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the cause is not visually evident, connect the diagnostic
tool to the data link connector and select the vehicle to be tested from the diagnostic tool
menu. If the diagnostic 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 position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. GO to Pinpoint Test PC. See: Communications Network/Pinpoint
Tests/Pinpoint Test PC (Precheck)
Pinpoint Test PC (Precheck)
PINPOINT TEST PC: DATA LINK DIAGNOSTICS NETWORK TEST
Test PC1
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ABS/TC Module Or Stability Assist Module C155
Data Link C251
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3972
Driver Seat Module (DSM) C341g
Electronic Automatic Temperature Control (EATC) C228b
In-line C126M, C126F
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3973
In-line C263M, C263F
In-line C408M, C408F, Part 1
In-line C408M, C408F, Part 2
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In-line C2095M, C2095F
In-line C2108M, C2108F
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In-line C3050M, C3050F
Instrument Cluster C220b
Parking Aid Module C4014
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
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Powertrain Control Module (PCM) C175a
Restraint Control Module (RCM) C310a
Tire Pressure Monitor Module C3183, Part 1
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Tire Pressure Monitor Module C3183, Part 2
Vehicle Security Module C3008f
4-Wheel Drive (4WD) Control Module C281b
Test A
PINPOINT TEST A: THE VEHICLE SECURITY MODULE DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
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Test A1-A3
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Test A4
Normal Operation
The vehicle security module communicates with the diagnostic tool through the UART based
protocol (UBP) communications network circuit 693 (OG). If circuit 693 (OG) becomes open or
shorted to ground communications to that module will not be possible. Check circuit 693 (OG)
between the vehicle security module C3008f and the DLC C251. Total resistance values must not
be more than 5 ohms. If the resistance is more than 5 ohms there is an open in circuit 693 (OG),
damage to the DLC C251, damage to the vehicle security module C3OO8f, or a problem in the
in-line connector C2095.
Possible Causes
- circuit 693 (OG) shorted to ground or open
- C3OO8f
- in-line C2095
- DLC C251
- vehicle security module
Test B
PINPOINT TEST B: THE 4-WHEEL DRIVE (4WD) CONTROL MODULE DOES NOT RESPOND
TO THE DIAGNOSTIC TOOL
Test B1
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Test B2-B5
Normal Operation
The 4WD control module communicates with the diagnostic tool through the UART based protocol
(UBP) communications network circuit 693 (OG). If circuit 693 (OG) becomes open or shorted to
ground communications to that module will not be possible. Check circuit 693 (OG) between the
4WD control module C281b and the DLC C251. Total resistance values must not be more than 5
ohms. If the resistance is more than 5 ohms there is an open in circuit 693 (OG), damage to the
DLC C251, damage to the 4WD control module C281b, or a problem in the in-line connectors
C2108.
Possible Causes
- circuit 693 (OG) shorted to ground or open
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3981
- in-line C2108
- 4WD control module C281b
- DLC C251
- 4WD control module
Test C
PINPOINT TEST C: THE RESTRAINT CONTROL MODULE (RCM) DOES NOT RESPOND TO
THE DIAGNOSTIC TOOL
Test C1-C3
Normal Operation
The RCM communicates with the diagnostic tool through the ISO 9141 communications network
circuit 70 (LB/WH). If circuit 70 (LB/WH) becomes open or shorted to ground communications to
that module will not be possible. Check circuit 70 (LB/WH) between the RCM C310a and the DLC
C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5
ohms there is an open in circuit 70 (LB/WH), damage to the DLC C251, or damage to the C310a.
Possible Causes
- circuit 70 (LB/WH) shorted to ground or open
- C310a
- DLC C251
- RCM
Test D
PINPOINT TEST D: THE TIRE PRESSURE MONITOR MODULE DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
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Test D1-D2
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Test D2-D4
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Test D4-D5
Normal Operation
The tire pressure monitor module communicates with the diagnostic tool through the SCP
communications network circuits 914 (TN/OG) and 915 (PK/LB). If one of the bus wires becomes
shorted to ground or voltage, or if some but not all termination resistors are lost, communications
can continue. Check circuits 914 (TN/OG) and 915 (PK/LB) between the tire pressure monitor
module C3183 and the data link connector (DLC) C251. Total resistance values must not be more
than 5 ohms. If the resistance is more than 5 ohms there is an open in circuit 914 (TN/OG) or 915
(PK/LB), damage to the DLC C251, damage to the tire pressure monitor module C3183, or a
problem in the in-line connector C2095.
Possible Causes
- circuit 914 (TN/OG) or 915 (PK/LB) shorted to ground or open
- tire pressure monitor module C3183
- in-line C2095
- DLC C251
- tire pressure monitor module
Test E
PINPOINT TEST E: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
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Test E1-E4
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Test E5-E7
Normal Operation
The DSM communicates with the diagnostic tool through the UART based protocol (UBP)
communications network circuit 693 (OG). If circuit 693 (OG) becomes open or shorted to ground
communications to that module will not be possible. Check circuit 693 (OG) between the DSM
C341c and the DLC C251. Total resistance values must not be more than 5 ohms. If the resistance
is more than 5 ohms there is an open in circuit 693 (OG), damage to the DLC C251, damage to the
DSM C341g, or a problem in the in-line connector C2095 or C3050.
Possible Causes
- circuit 693 (OG) shorted to ground or open
- C341g
- in-line C2095
- in-line C3050
- DLC C251
- DSM
Test F
PINPOINT TEST F: THE PARKING AID MODULE DOES NOT RESPOND TO THE DIAGNOSTIC
TOOL
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Test F1-F3
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Test F4-F7
Normal Operation
The parking aid module communicates with the diagnostic tool through the ISO 9141
communications network circuit 70 (LB/WH). If circuit 70 (LB/WH) becomes open or shorted to
ground communications to that module will not be possible. Check circuit 70 (LB/WH) between the
parking aid module C4014 and the DLC C251. Total resistance values must not be more than 5
ohms. If the resistance is more than 5 ohms there is an open in circuit 70 (LB/WH), damage to the
DLC C251, damage to the parking aid module C4014, or a problem in the in-line connector C2095
or C408.
Possible Causes
- circuit 70 (LB/WH) shorted to ground or open
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3989
- C4014
- in-line C2095
- in-line C408
- DLC C251
- parking aid module
Test G
PINPOINT TEST G: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO
THE DIAGNOSTIC TOOL
Test G1-G2
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Test G2-G4
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Test G4-G5
Normal Operation
The PCM communicates with the diagnostic tool through the SCP communications network circuits
914 (TN/OG) and 915 (PK/LB). If one of the bus wires becomes shorted to ground or voltage, or if
some but not all termination resistors are lost, communications can continue. Check circuits 914
(TN/OG) and 915 (PK/LB) between the PCM C175a and the data link connector (DLC) C251. Total
resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an
open in circuit 914 (TN/OG) or 915 (PK/LB), damage to the DLC C251, damage to the PCM
C175a, or a problem in the in-line connector C263.
Possible Causes
- circuits 914 (TN/OG) or 915 (PK/LB) shorted to ground or open
- PCM C175a
- in-line C263
- DLC C251
- PCM
Test H
PINPOINT TEST H: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL
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Test H1-H3
Normal Operation
The instrument cluster communicates with the diagnostic tool through the SCP communications
network circuits 914 (TN/OG) and 915 (PK/LB). If one of the bus wires becomes shorted to ground
or voltage, or if some but not all termination resistors are lost communications can continue. Check
circuits 914 (TN/OG) and 915 (PK/LB) between the instrument cluster C220b and the data link
connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is
more than 5 ohms there is an open in circuit 914 (TN/OG) or 915 (PK/LB), damage to the DLC
C251, or damage to the instrument cluster C220b.
Possible Causes
- circuits 914 (TN/OG) or 915 (PK/LB) shorted to ground or open
- instrument cluster C22Ob
- DLC C251
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3993
- instrument cluster
Test I
PINPOINT TEST I: THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL
Test I1-I2
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Test I2-I3
Normal Operation
Under normal operation the EATC module communicates with the diagnostic tool through the SCP
communications network circuits 914 (TN/OG) and 915 (PK/LB). If one of the bus wires becomes
shorted to ground or voltage, or if some but not all termination resistors are lost, communications
can continue. Check circuits 914 (TN/OG) and 915 (PK/LB) between the EATC module C228b and
the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the
resistance is more than 5 ohms there is an open in circuit 914 (TN/OG) or 915 (PK/LB), damage to
the DLC C251, or damage to the EATC module C228b.
Possible Causes
- circuits 914 (TN/OG) or 915 (PK/LB) shorted to ground or open
- C228b
- DLC C251
- EATC module
Test J
PINPOINT TEST J: THE ABS/TC MODULE OR STABILITY ASSIST MODULE DOES NOT
RESPOND TO THE DIAGNOSTIC TOOL
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Test J1-J3
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Test J4-J5
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Test J6-J7
Normal Operation
The ABS/TC module or stability assist module communicates with the diagnostic tool through the
SCP communications network circuits 914 (TN/OG) and 915 (PK/LB). If one of the bus wires
becomes shorted to ground or voltage, or if some but not all termination resistors are lost
communications can continue. Check circuits 914 (TN/OG) and 915 (PK/LB) between the ABS/TC
module or stability assist module C155 and the DLC C251. Total resistance values must not be
more than 5 ohms. If the resistance is more than 5 ohms there is an open in circuit 914 (TN/OG) or
915 (PK/LB), damage to the DLC C251, damage to the ABS/TC module or stability assist module
C155, or a problem in the in-line connector C263 or C126.
Possible Causes
- circuits 914 (TN/OG) or 915 (PK/LB) shorted to ground or open
- C155
- in-line C263
- in-line C126
- DLC C251
- ABS/TC Module or Stability Assist Module
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 3998
Test K
PINPOINT TEST K: NO STANDARD CORPORATE PROTOCOL (SCP) NETWORK
COMMUNICATION
Test K1-K2
Test K3-K4
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Test K5-K7
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Test K8-K9
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4001
Test K10-K11
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4002
Test K12-K14
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4003
Test K15-K16
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4004
Test K17-K19
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4005
Test K20-K22
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Test K23-K25
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Test K26-K29
Normal Operation
The powertrain control module (PCM), ABS/TC module or stability assist module, electronic
automatic temperature control (EATC) module, tire pressure monitor module, and the instrument
cluster communicate with the diagnostic tool through the SCP communications network circuits 914
(TN/OG) and 915 (PK/LB). If one of the bus wires become shorted to ground or voltage, or if some
but not all termination resistors are lost, communications can continue. If a module is lost due to
internal concerns, communications can continue to all other modules. Check circuits 914 (TN/OG)
and 915 (PK/LB) between the PCM C175a, tire pressure monitor module C3183, ABS/TC module
or stability assist module C155, EATC module C228b, instrument cluster C220b, and the DLC
C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5
ohms there is an open in circuit 914 (TN/OG) or 915 (PK/LB), damage to the DLC C251, damage
to the PCM C175a, tire pressure monitor module C3183, ABS/TC module or stability assist module
C155, EATC module C228b, instrument cluster C220b, a problem in the in-line connectors C2095,
C263, C126 or an internal problem with the PCM, ABS/TC module or stability assist module, EATC
module, tire pressure monitor module, or the instrument cluster. If, after individual checks of each
circuit leading to a module show resistance values less than 5 ohms and no in-line connector
issues present, the data link diagnostics test must be run with the module in question
disconnected. If the data links diagnostics test passes with the module in question disconnected it
is the source of the concern and should be removed and a new module installed.
Possible Causes
- circuits 914 (TN/OG) or 915 (PK/LB) shorted to ground or open
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4008
- in-line C2095
- in-line C263
- in-line C126
- DLC C251
- ABS/TC Module or Stability Assist Module
- PCM
- EATC module
- instrument cluster
- tire pressure monitor module
Test L
PINPOINT TEST L: NO INTERNATIONAL STANDARDS ORGANIZATION (ISO) 9141 NETWORK
COMMUNICATION
Test L1-L2
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Test L3-L6
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Test L7-L10
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4011
Test L11-L12
Normal Operation
The reverse parking aid module and the restraint control module (RCM) communicate with the
diagnostic tool through the ISO 9141 communications network circuit 70 (LB/WH). If circuit 70
(LB/WH) becomes open or shorted to ground, communications to that module will not be possible.
Check circuit 70 (LB/WH) between the parking aid module, RCM and the DLC C251. Total
resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an
open in circuit 70 (LB/WH), damage to the DLC C251, damage to the parking aid module, RCM, or
a problem in one of the in-line connectors C2095 or C408. If, after individual checks of each circuit
leading to a module show resistance values less than 5 ohms and no in-line connector issues
present, the data link diagnostics test must be run with the module in question disconnected. If the
data links diagnostics test passes with the module in question disconnected it is the source of the
concern and should be removed and a new module installed.
Possible Causes
- circuit 70 (LB/WH) shorted to ground or open
- in-line C2095
- in-line C408
- DLC C251
- parking aid module
- RCM
Test M
PINPOINT TEST M: NO UART BASED PROTOCOL (UBP) NETWORK COMMUNICATION
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Test M1-M4
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Test M5-M9
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Test M10-M13
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Test M14-M17
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Test M18-M22
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Test M23-M24
Normal Operation
The driver seat module (DSM), vehicle security module, and the 4-wheel drive (4WD) control
module communicate with the diagnostic tool through the UART based protocol (UBP)
communications network circuit 693 (OG). If circuit 693 (OG) becomes open or shorted to ground,
communications to that module will not be possible. Check circuit 693 (OG) between the DSM,
vehicle security module, and the 4WD control module and the DLC C251. Total resistance values
must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in circuit 693
(OG), damage to the DLC C251, damage to the DSM, vehicle security module, the 4WD control
module, instrument cluster, or a problem in one of the in-line connectors C2095, C2108 or C408. If,
after individual checks of each circuit leading to a module show resistance values less than 5 ohms
and no in-line connector issues present, the data link diagnostics test must be run with the module
in question disconnected. If the data links diagnostics test passes with the module in question
disconnected it is the source of the concern and should be removed and a new module installed.
Possible Causes
- DLC C251
- 693 (OG)
- in-lines C2095, C2108 or C408
- diagnostic tool
- vehicle security module
- DSM
- 4WD control module
- instrument cluster
Test N
PINPOINT TEST N: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL (UBP)
Test N1
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Test N2-N3
Normal Operation
The instrument cluster communicates with the diagnostic tool through the UART based protocol
(UBP) communications network circuit 693 (OG). If circuit 693 (OG) becomes open or shorted to
ground communications to that module will not be possible. Check circuit 693 (OG) between the
instrument cluster and the DLC C251. Total resistance values must not be more than 5 ohms. If the
resistance is more than 5 ohms there is an open in circuit 693 (OG), damage to the DLC C251,
damage to the instrument cluster C22Ob.
Possible Causes
- circuit 693 (OG) shorted to ground or open
- instrument cluster C220b
- DLC C251
- instrument cluster
Test O
PINPOINT TEST O: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE
DIAGNOSTIC TOOL
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Test O1-O4
Normal Operation
The diagnostic tool is connected to the DLC C251 to communicate with the standard corporate
protocol (SCP), UART based protocol (UBP), and the international standards organization (ISO)
9141 communications networks. If communication can not be established, the diagnostic tool and
the DLC C251 must be checked for damaged. If the diagnostic tool and the DLC C251 are ok
circuits 1001 (WH/YE), 1205 (BK), and 570 (BK/WH) must be checked for an open condition.
Possible Causes
- DLC C251
- diagnostic tool
- circuit 1001 (WH/YE) open circuit
- circuit 1205 (BK) open circuit
- circuit 570 (BK/WH) open circuit
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Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4020
Symptom Chart, Part 1
Symptom Chart, Part 2
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Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical Central junction box (CJB) fuses: F2.24 (5A)
- F2.1 (30A)
- Battery junction box (BJB) fuse F1.29 (60A)
- Wiring harness
- Connector(s)
- Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector
(DLC) located beneath the instrument panel and
select the vehicle to be tested from the diagnostic tool menu. If the diagnostic 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 position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds
with:
- UBP = ALL ECUS NO RESP/NOT EQUIP, GO to Pinpoint Test M. See: Communications
Network/Pinpoint Tests/Pinpoint Tests/Test M
- NO RESPONSE/NOT EQUIP for DSM, GO to Pinpoint Test E. See: Communications
Network/Pinpoint Tests/Pinpoint Tests/Test E
- SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the DSM.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions
7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to
continue diagnostics.
Driver Seat Module (DSM) C341e
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Driver Seat Module (DSM) C341g, Part 1
Driver Seat Module (DSM) C341g, Part 2
Test P
PINPOINT TEST P: NO COMMUNICATION WITH THE DRIVER SEAT MODULE (DSM)
Test P1
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Test P2-P4
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Test P5
Normal Operation
The power driver seat is controlled by the DSM only when the vehicle is equipped with the
programmable/recall memory option. Power is supplied through central junction box (CJB) fuses:
20 (5A), 1 (30A) and battery junction box (BJB) fuse 29 (60A) and 1 (60A) on Circuits 1003
(GY/YE), 566 (DG) and grounded through circuit 1203 (BK/LB) and 1205 (BK).
Possible Causes
- CJB fuses: 20 (5A)
- 1 (30A)
- BJB fuses: 1 (60A)
- 29 (60A)
- circuit 1003 (GY/YE) open or shorted to ground
- circuit 566 (DG) open or shorted to ground
- circuit 1203 (BK/LB) open
- circuit 1205 (BK) open
Symptom Chart
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
electrical damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuses: 1.1 (60A)
- 1.29 (60A)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 4025
- Central junction box (CJB) fuses: F2.20 (5A)
- F2.1 (30A)
- Wiring harness
- Connectors
- Circuitry
3. If the concern remains after the inspection, connect the diagnostic tool to the data link connector
(DLC) located beneath the instrument panel and
select the vehicle to be tested from the diagnostic tool menu. If the diagnostic 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 position.
4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds
with:
- UBP = ALL ECUS NO RESP/NOT EQUIP, GO to Pinpoint Test M. See: Communications
Network/Pinpoint Tests/Pinpoint Tests/Test M
- NO RESPONSE/NOT EQUIP for vehicle security module, GO to Pinpoint Test A. See:
Communications Network/Pinpoint Tests/Pinpoint Tests/Test A
- SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase
the continuous DTCs and carry out self-test diagnostics for the vehicle security module.
6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index
to continue diagnostics. See: Diagnostic Trouble
Code Descriptions
7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to
continue diagnostics.
Test Q
PINPOINT TEST Q: NO COMMUNICATION WITH THE VEHICLE SECURITY MODULE
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Test Q1-Q2
Test Q2-Q3
Normal Operation
The vehicle security module controls the remote keyless entry and computer-operated locks and
vehicle security. The vehicle security module receives power through BJB fuses 2 (30A) and CJB
fuse 2 (1OA). From the fuses power is delivered to the module through circuits 456 (DG/OG), 645
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(WH/LB) and is grounded on circuit 1205 (BK).
Possible Causes
- battery junction box (BJB) fuse 2 (30A)
- central junction box (CBJ) fuse 20 (5A)
- circuit 645 (WH/LB) open or shorted to ground
- circuit 456 (DG/OG) open or shorted to ground
- circuit 1205 (BK) open
- vehicle security module
Vehicle Security Module C3008d
Vehicle Security Module C3008e
Symptom Chart
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Service and Repair > Driver Seat Module (DSM)
Information Bus: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Worldwide Diagnostic System (WDS)
SPECIAL TOOL(S)
CAUTION: Prior to removal of the DSM, it is necessary to upload module configuration information
to a diagnostic tool. This information needs to be downloaded into the new module once installed.
Refer to Module Configuration.
REMOVAL
1. Remove the driver seat.
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Information > Service and Repair > Driver Seat Module (DSM) > Page 4030
2. Remove the components in the order indicated in the illustration and the table.
INSTALLATION
1. To install, reverse the removal procedure.
Item 3: Driver Seat Module Installation Note
1. Once the module is installed, it is necessary to download the module configuration information
from the diagnostic tool into the new module.
Refer to Module Configuration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Service and Repair > Driver Seat Module (DSM) > Page 4031
Information Bus: Service and Repair Vehicle Security Module
VEHICLE SECURITY MODULE
Worldwide Diagnostic System (WDS)
SPECIAL TOOL(S)
CAUTION: Prior to removal of the vehicle security module, it is necessary to upload module
configuration information to a diagnostic tool. This information needs to be downloaded into the
new module once installed. Refer to Module Configuration.
REMOVAL
1. Remove the right rear quarter trim panel.
2. Remove the components in the order indicated in the illustration and the table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Service and Repair > Driver Seat Module (DSM) > Page 4032
Item 3: Vehicle Security Module Installation Note
1. Once the module is installed, it is necessary to download the module configuration information
from the diagnostic tool into the new module.
Refer to Module Configuration.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Service and Repair > Page 4033
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor: Locations
View 151-55
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 4037
View 151-77
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 4038
Knock Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 4039
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4043
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4044
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4045
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) (Figure 17) 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 18).
- 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 Symptom Charts.
- 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.
Malfunction Indicator Lamp (MIL)
CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Oxygen Sensor Bank Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Oxygen Sensor Bank Locations > Page 4053
Oxygen Sensor: Locations Exhaust System Oxygen Sensor Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Oxygen Sensor: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4056
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4057
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4058
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4059
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4060
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4061
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4062
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4063
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4064
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4065
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4066
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4067
Oxygen Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4068
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4069
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4070
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4071
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4072
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4073
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4074
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4075
Oxygen Sensor: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4076
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 4077
Oxygen Sensor: Application and ID
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 4078
Part 2 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 4079
Oxygen Sensor: Service and Repair
HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. With the vehicle in neutral, position it on a hoist.
2. For the RH side catalytic converter, remove the two bolts and position the heat shield aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 4080
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 2: Catalyst Monitor Removal Note
1. Using the special tool, remove the catalyst monitor sensors.
Item 3: Heated Oxygen Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 4081
1. Using the special tool, remove the heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
Item 3: Heated Oxygen Sensor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensors.
Item 2: Catalyst Monitor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 4082
Socket, Exhaust Gas Oxygen Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set >
Page 4087
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set >
Page 4088
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability Issues/DTC's Set >
Page 4089
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4090
Pressure Feedback Exhaust Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4091
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4092
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4093
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
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Sensor, EGR > Component Information > Technical Service Bulletins > Page 4094
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Locations > Central Security Module
View 151-44
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View 151-67
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4104
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4105
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4106
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4108
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4109
Symbols Part 2
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4110
Symbols Part 3
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4111
Symbols Part 4
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4112
Symbols Part 5
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4113
Systems Overview
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4114
Body Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4115
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4116
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4117
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4118
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4119
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4120
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4121
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4122
Body Control Module: Connector Views
Central Security Module
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4123
Driver Seat Module
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> Page 4124
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and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions
> Page 4125
Body Control Module: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
59-1
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59-2
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation
Electronic Throttle Control Module: Description and Operation
Torque Based Electronic Throttle Control (ETC)
Overview
Torque Based Electronic Throttle Control (ETC) is a strategy that delivers a transmission output
shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes the Visteon Gen
II electronic throttle body (replaces throttle cable).
Torque based ETC strategy was developed mainly to improve fuel economy. This is possible by
not coupling the throttle angle to pedal position, which enables various fuel economy schemes and
technologies.
Background "Why Torque Based ETC"
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts. In other words the engine shifts can result is an engine lugging condition (low RPM
and low manifold vacuum) while still delivering the same torque requested by the driver. It should
be noted that the ETC system includes a wrench light on the instrument cluster that illuminates
when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon"
light.
It also enables many fuel economy/emission improvement technologies such as:
- VCT (deliver same torque during transitions)
- Continuously varying Transmission (CVT)
- Hybrid Electric Vehicle (HEV)
Torque based ECT also results is a less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other generic benefits of ETC are:
- Eliminate cruise control actuators
- Eliminate ISC Bypass actuator
- Better airflow range
- Packaging (no cable)
Electronic Throttle Body
The Gen II electronic throttle body (Figure 148) has the following characteristics
1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the
throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has
the motor under the bore parallel to the plate shaft. The motor housing is
integrated into the main housing (in general this is more difficult to package). The in-series design
has a separate motor housing that protrudes out and offers more packaging flexibility.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle with no
power applied. This is for limp home reasons (force of plunger spring is 2X main spring). Default
angle is usually set to result in a top vehicle speed of 30 MPH (typically 7 to 8 degrees from
hard-stop angle).
4. The closed throttle plate hard stop is used to avoid the throttle from binding is the bore (~0.75
degree). This hard stop is non-adjustable and is set
to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the plate or use
plate sealant. The hole in the plate is not required
with ETB because the required idle airflow is provided by the plate angle, which also is the reason
there is no IAC.
6. The system has two throttle position sensors. Redundant throttle position signals are required for
monitor reasons. TP1 has a negative slope
(increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing
voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control
strategy as the indication of throttle position. The TP assembly requires four wires.
- 5 V Reference Voltage
- Signal Return (ground)
- TP1 voltage with negative voltage slope (5-0)
- TP2 voltage with positive voltage slope (0-5)
Accelerator Pedal Position Sensors (APPS)
The ETC strategy uses pedal position sensors as an input to determine the driver demand.
1. There are three pedal position sensors required for safety monitor reasons. APP1 has a negative
slope (increasing angle, decreasing voltage) and
APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal
operation APP1 is used as the indication of pedal
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position by the strategy.
2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires
and pins) between the PCM and APPS assembly.
- 2- (5 V Reference Voltage)
- 2- (Signal Return "ground")
- APP1 voltage with negative voltage slope (5-0)
- APP2 voltage with positive voltage slope (0-5)
- APP3 voltage with positive voltage slope (0-5)
3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault.
The PCM knows if a signal is wrong by
calculating where it should be, inferred by the other signals. A safe value will be substituted for a
faulty signal if two out of the three signals are bad.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4139
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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ON/DTC's > Page 4159
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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ON/DTC's > Page 4161
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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ON/DTC's > Page 4162
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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ON/DTC's > Page 4163
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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ON/DTC's > Page 4164
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming
Procedures
Engine Control Module: All 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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Procedures > Page 4169
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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Procedures > Page 4170
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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Service Bulletins for Engine Control Module: > 03-13-6 > Jul > 03 > Engine Controls - No Start Condition
Technical Service Bulletin # 03-13-6 Date: 030707
Engine Controls - No Start Condition
Article No. 03-13-6
07/07/03
^ DRIVEABILITY - NO-CRANK - SERVICE TIPS
^ ELECTRICAL - NO-CRANK - SERVICE TIPS
FORD: 2002-2003 EXPLORER
LINCOLN: 2003 AVIATOR
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002/2003 Explorer 4dr, Mountaineer, and 2003 Aviator vehicles may exhibit a
no-crank condition
ACTION Refer to the following diagnostic Service Tips for details.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Disclaimer
Service Information
NOTE
PCM REPLACEMENT IS GENERALLY NOT AN EFFECTIVE REPAIR FOR NO-CRANK
CONDITIONS.
Perform Procedure 1, 2 or 3 depending on the specific no-crank symptoms experienced.
1. INTERMITTENT NO-CRANK OR CUSTOMER COMPLAINT CANNOT BE DUPLICATED
NOTE
PERFORM THE FOLLOWING INSPECTIONS/REPAIRS IN THE SEQUENCE SHOWN.
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS Diagnostic Trouble Code's (DTC's) exist, go to PATS diagnostic in Explorer/Mountaineer
or Aviator Workshop Manual Section 419-01.
^ If powertrain DTC codes exist go to PCED Manual Section 4.
b. Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB):
^ If connection is loose, torque battery cable terminal nut on BJB to 144 lb-in. (16.4 N.m).
c. Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
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d. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
re-install. Torque to 95 lb-in. (10.8 N.m).
e. Inspect connections in Battery Junction Box (BJB):
^ Inspect for discoloration of PCM power relay terminals (indicating poor connection to relay
terminals in BJB). See Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of
relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check seating on the starter, PCM and fuel pump relays.
NOTE
DO NOT REPLACE PCM IF NO CRANK CONDITION CANNOT BE REPRODUCED. PCM
REPLACEMENT IS NOT AN EFFECTIVE REPAIR FOR INTERMITTENT NO-CRANK.
f. When all inspections are complete, clear DTC's, restore vehicle, and return to customer.
2. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND DASHES IN ODOMETER
DISPLAY
NOTE
DASHES IN ODOMETER DISPLAY INDICATE NO COMMUNICATION BETWEEN THE PCM
AND THE INSTRUMENT CLUSTER.
Assure good battery charge condition.
a. Inspect PCM power ground for good connection. Ground connection G104-Explorer/Mountaineer
or G108-Aviator is located on the bulkhead above PCM as illustrated in Explorer/Mountaineer
Wiring Diagram 151-17 or Aviator Wiring Diagram 151-1:
^ If connection is loose, remove ground attaching bolt from bulkhead. Clean and inspect bolt and
reinstall. Torque to 95 lb-in. (10.8 N.m).
b. Check PCM power connections in the Battery Junction Box (BJB). With key on, engine off,
perform the following checks while monitoring restoration of communication to the PCM either
through odometer display or NGS tester:
^ Check seating of the PCM power relay in the Battery Junction Box (BJB). See
Explorer/Mountaineer/Aviator Wiring Diagram, Section 11, for illustration of relay locations in BJB.
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check PCM power relay by temporarily swapping with relay from unrelated circuit (fuel pump or
other equivalent relay).
c. Check PCM ground integrity at PCM connector:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 1.
^ With one lead of ohmmeter connected to known good ground, check pins 24, 25, 26, and 27 as
shown on Figure 1.
^ If measured resistance is greater than 5 ohms at either pin, diagnose and repair ground fault.
d. Check PCM power supply at PCM connector:
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^ Turn ignition to "ON" position, engine off.
^ With one lead of voltmeter connected to known good ground, check pins 32 and 33 on bottom
PCM connector as shown on Figure 1.
^ If measured power supply is lower than battery voltage by 1 volt or more, diagnose and repair
power supply circuit.
e. If PCM power and ground are within specification, perform PCM Quick Test to confirm
communication status with PCM.
f. PCM should be replaced only under the following conditions:
^ PCM power supply and ground is within specification, and
^ Symptoms of both no-crank and dashes in odometer display continues, and
^ Quick Test confirms no-communication with PCM
3. CUSTOMER COMPLAINT DUPLICATED - NO-CRANK AND NORMAL ODOMETER DISPLAY
Assure good battery charge condition.
a. Perform PCM Quick Test:
^ If PATS DTC's exist, go to PATS diagnostic in Explorer/Mountaineer/Aviator Workshop Manual
Section 419-01.
b. Perform starting system circuit test:
^ Remove bottom PCM connector (C175A-Explorer/Mountaineer, C175B-Aviator) from PCM.
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^ Refer to PCM connector face diagram in Figure 2.
^ Connect jumper from known good ground to pin 39 in PCM connector per Figure 2 (this is starter
relay ground circuit).
^ With shift selector in Park and pin 39 grounded, attempt to crank engine by turning ignition to
start position.
^ If starter does not crank, proceed to step 3c.
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^ If starter cranks, proceed to step 3d.
a. Check starter circuit in following sequence:
^ Check for loose connection of the B+ battery cable to the Battery Junction Box (BJB). If
connection is loose, torque battery cable terminal nut on BJB to 144 lb-in (16.4 N.m).
^ Check for proper torque on starter solenoid terminal nuts. The B+ terminal nut should be torqued
to 144 lb-in. (16.4 N.m) and the S terminal nut should be torqued to 65 lb-in. (7.4 N.m).
^ Inspect connections in Battery Junction Box (BJB)
^ Wiggle wires leading to the BJB and check for loose connections.
^ Check starter relay by temporarily swapping with relay from unrelated circuit. See
Explorer/Mountaineer or Aviator Wiring Diagram, Section 11, for illustration of relay locations in
BJB.
If inspections above do not result in repair of crank function, proceed to Pinpoint Test A, Section
303-04A of Explorer/Mountaineer/Aviator Workshop Manual.
d. The PCM should be replaced only under the following conditions:
^ Starter cranks with diagnostic step 3b above
^ No PATS DTC's exist
^ No evidence of damage to female side of pin 39 in PCM connector.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
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Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
Engine Control Module: All 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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Page 4185
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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Page 4186
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4187
Engine Control Module: Locations
View 151-7
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4188
View 151-17
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views
Engine Control Module: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4191
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4192
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4193
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4194
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically
Eraseable Programmable Read Only Memory
Engine 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 described under Programming the VID
Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635,
P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be
tailored to accommodate various hardware/parameter 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 is one of the main causes for code: P1639. This is described under
Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The
VID block contains many items used by the strategy for a variety of functions. Some of these items
include the 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
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/or incapable of
communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and
execute Module/Parameter reprogramming referring to the manufacturers users manual. Important,
make certain that all parameters are included. Failure to properly program Tire Size in revolutions
per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or
Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be
instructed to contact the "AS BUILT" data center for the information needed to manually update the
VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is
corrupt. For Ford L-M technician's, contact your National Hotline or the Professional Technician
Society (PTS) web sight 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
accomodate 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically
Eraseable Programmable Read Only Memory > Page 4197
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL
1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS)
hook-up procedure.
Connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and
obtain configuration data. All programmable module information will automatically be retrieved by the WDS.
2. Disconnect the battery ground cable.
3. Remove the glovebox door assembly.
1 Open the glovebox door.
2 Push in on the sides of the glovebox door to release the retainers.
3 Remove the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically
Eraseable Programmable Read Only Memory > Page 4198
4. Remove the components in the order listed in the illustration and table.
Item 4: Powertrain Control Module (PCM) Removal Note
1. Remove the PCM and bracket as an assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Powertrain Control Module (PCM) Installation Note
1. Install the PCM and bracket as an assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4202
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4203
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4204
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4210
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4211
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Brake Pressure Switch > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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View 151-78
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Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4220
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 4225
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 4226
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL
1. Disconnect the battery ground cable. 2. Drain the cooling system.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
View 151-8
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4230
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4231
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
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View 151-78
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions
Fuel Tank Pressure Sensor: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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4240
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
View 151-55
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 4244
View 151-77
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 4245
Knock Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 4246
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations
> Page 4251
Oxygen Sensor: Locations Exhaust System Oxygen Sensor Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Oxygen Sensor: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4254
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4255
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4256
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4257
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4258
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4259
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4260
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4261
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4262
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4263
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4264
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4265
Oxygen Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4266
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4267
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4268
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4269
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4270
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4271
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4272
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4273
Oxygen Sensor: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4274
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4275
Oxygen Sensor: Application and ID
Part 1 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4276
Part 2 Of 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4277
Oxygen Sensor: Service and Repair
HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR
Socket, Exhaust Gas Oxygen Sensor
SPECIAL TOOL(S)
REMOVAL
1. With the vehicle in neutral, position it on a hoist.
2. For the RH side catalytic converter, remove the two bolts and position the heat shield aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4278
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 2: Catalyst Monitor Removal Note
1. Using the special tool, remove the catalyst monitor sensors.
Item 3: Heated Oxygen Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4279
1. Using the special tool, remove the heated oxygen sensors.
INSTALLATION
1. To install, reverse the removal procedure.
Item 3: Heated Oxygen Sensor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensors.
Item 2: Catalyst Monitor Installation Note
1. Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4280
Socket, Exhaust Gas Oxygen Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4285
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4286
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4287
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4288
Pressure Feedback Exhaust Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4289
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4290
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4291
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4292
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4296
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4297
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4298
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4299
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4303
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4304
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4305
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
4306
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 4310
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Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 4311
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 4312
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 4313
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4317
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4318
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4319
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 4320
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
Variable Cam Timing System
Overview
There are four possible types of Variable Cam Timing (VCT) Systems. The 2003 Escort/Tracer are
Exhaust Phase Shifting system (EPS). The exhaust cam is the active cam and is being retarded.
The 2003 Lincoln LS, T-Bird and Focus SVT vehicles have Intake Phase Shifting system (IPS). A
intake phase shifting system will move the intake cam in the advance direction. The other two
possible systems are Dual Equal (DEPS) both intake and exhaust cams are phase shifted equally
as well as Dual Independent Phase Shifting (DIPS) where the cams are shifted independently. The
systems have three operational modes; idle, part throttle, wide open throttle and a default mode. At
idle and (low engine speeds with closed throttle) the phase angle is controlled by air flow and
Engine Coolant Temperature (ECT). At part and wide open throttle the Powertrain Control Module
(PCM) controls cam timing based on engine RPM, load, and Throttle Position (TP). VCT systems
provide reduced emissions and enhance engine power, fuel economy and idle quality. IPS systems
have the added benefit of improve torque. In addition a VCT system will eliminate the need for an
external Exhaust Gas Recirculation (EGR) system. The elimination of EGR system is accomplished
by controlling the overlap in valve opening between the intake valve opening and exhaust valve
closing. Increased vehicle reliability is achieved with the elimination of the EGR system.
Variable Cam Timing
Variable Cam Timing System
The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid,
a CMP (Camshaft Position Sensor) and trigger wheel. The CMP trigger wheel has a number of
equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1).
Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1
tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP
signal for that bank. A CKP (Crankshaft Position Sensor) provides the PCM (powertrain control
module) with crankshaft positioning information in 10 degree increments (Figure 130).
1. The PCM receives input signals from the Intake Air Temperature (IAT), ECT (engine coolant
temperature), CMP, TP (throttle position), MAF
(Mass Air Flow) and CKP to determine the operating conditions of the engine. At idle (low engine
speeds and closed throttle) the PCM controls camshaft position based on air and coolant
temperatures. During part and wide open throttle, camshaft position is determined by engine RPM,
load and throttle position. The VCT system will not operate until the engine is at normal operating
temperature.
2. The VCT system is enabled by the PCM when the proper conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The PCM calculates and determines the desired
camshaft position. It will continually update the VCT solenoid duty cycle until desired
positioning is achieved. A difference between the desired and actual camshaft position represents
a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the
camshaft in a default position if a fault is detected.
5. Oil flows to either side of the piston chamber in the VCT assembly, which changes the linear
piston motion to a rotational motion that
advances or retards the camshaft.
Hardware
Variable Cam Timing (VCT) Solenoid Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Page 4324
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 131) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil in the VCT assembly. As the PCM controls the duty cycle of the
solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100%
represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by
dithering (oscillating) the solenoid valve duty near 50%.
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The VCT unit assembly (Figure 132) 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, a pressure
differential occurs forcing the piston to move. This movement 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information >
Description and Operation
Air Injection: Description and Operation
SECONDARY AIR INJECTION (AIR) SYSTEMS
Overview
The Secondary Air Injection (AIR) system controls emissions during the first 20 to 120 seconds of
engine operation by forcing air downstream into the exhaust manifolds to oxidize the hydrocarbons
and carbon monoxide created by running rich at start up.
Electric Secondary Air Injection System
Dual Or Single AIRD Valve Electric Secondary Air Injection (AIR)
The Electric Secondary Air Injection (AIR) system consists of an Electric AIR Pump (EAP), single
or dual combination check air injection diverter (AIR diverter) valve(s), an AIR bypass solenoid, a
solid state relay, Powertrain Control Module (PCM) and connecting wires and vacuum hoses.
1. The PCM requires Engine Coolant Temperature (ECT), Intake Air Temperature (IAT) and
Crankshaft Position (CKP) inputs to initiate
Secondary Air Injection function.
2. When the engine is started, the strategy will determine when to enable the EAP. The PCM
signals the solid state relay and the AIR bypass
solenoid, after a (5 to 10) second delay, to begin system operation. Once the catalyst is lit-off, the
PCM then signals the solid state relay to stop AIR pump operation and to close the AIR bypass
solenoid from supplying vacuum to the AIR diverter valve(s).
3. The solid state relay provides the start-up signal and will switch the high current required to
operate the AIR pump. 4. The AIR bypass solenoid applies a vacuum to the AIR diverter valve(s)
causing it to open and to allow air to flow into the exhaust manifolds. 5. The vacuum check valve
controls vacuum bleed-off to solenoid. 6. The function of the splash cap if equipped is to provide
the AIR pump with a source of dry air. 7. The electric AIR pump delivers the required amount of air
to control emissions during engine operation. Air is forced into the exhaust
manifolds to oxidize the hydrocarbons and carbon monoxide created by running rich at start up.
Hardware
Electric AIR Pump
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information >
Description and Operation > Page 4329
Electric Air Pump
The electric AIR pump 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.
AIR Bypass Solenoid
Secondary Air Injection Bypass Solenoid
The secondary air injection bypass (AIR bypass) solenoid 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.
AIR Diverter Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information >
Description and Operation > Page 4330
Air Injection Diverter (AIR Diverter) Valve
The secondary air injection diverter (AIR diverter) valve 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.
Solid State Relay
Solid State Relay
The solid state relay 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).
Vacuum Check Valves
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > System Information >
Description and Operation > Page 4331
Vacuum Check Valve
A vacuum check valve 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation
Catalytic Converter: Description and Operation
Catalyst and Exhaust Systems
The Catalytic Converter and Exhaust systems work together to control the release of harmful
engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen
(N), carbon dioxide (CO 2) and water vapor (H2O). However, it also contains carbon monoxide
(CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). CO,
NOx, 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, front heated
oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications, more than one catalyst will be used between the front and rear exhaust pipes.
Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD) system strategy in
the PCM. Refer to the Catalyst Efficiency Monitor-Federal Test Procedure at the beginning of
Section 1 for specific OBD catalyst monitor information.
The number of HO2S(s) used in the exhaust stream and the location of these sensors depend on
the vehicle emission certification level (i.e. LEV, ULEV, PZEV). Refer to (Figure 136) and (Figure
137) for typical HO2S stream locations and naming convention. On most vehicles only two HO2S
are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst will be
used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) will be utilized to
monitor catalyst efficiency. However, some Partial Zero Emission Vehicles (PZEV) will utilize three
HO2S sensors for each engine bank. The stream 1 sensors (HO2S11/HO2S21) before the catalyst
will be used for primary fuel control, the next group of sensors or stream 2 (HO2S12/HO2S22) is
utilized to monitor the light-off catalyst and the last group of sensors or stream 3
(HO2S13/HO2S23) is utilized for long term fuel trim control to optimize catalyst efficiency (Fore Aft
Oxygen Sensor Control). Currently Ford's PZEV vehicles use only a 4-cylinder engine, so only the
Bank 1 HO2S(s) will be utilized.
V-Engines
In-Line Engines
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4335
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
ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust
gases come in contact with the catalyst, they are changed into mostly harmless products. The
catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components
so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency
exceeds 50% is called catalyst light off. For most catalysts this point occurs at 475 to 575°F (246 to
301°C). A fast light catalyst is a three way catalyst (TWC) that is located as close to the exhaust
manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will
light off faster and reduce emissions quicker than the catalyst located under the body. Once the
catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that
catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high
conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly
controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly
decrease the conversion efficiency (Figure 138). For example a rich mixture will decrease the HC
and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency.
TWC Conversion Efficiency Chart
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. 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 (NOx) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter through
another HO2S mounted in the rear exhaust pipe (Figure 139) and then on into the muffler. Lastly,
the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
Note on some Partial Zero Emission Vehicles (PZEV), there will be a total of 3 HO2S in the
exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off
catalyst (stream 2) and the third (stream 3) is mounted after the light-off catalyst (Figure 140).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4336
Bank 1 Catalyst Two HO2S Configuration
Bank 1 Catalyst Three HO2S Configuration
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in-line
with the light off catalyst, or the underbody catalyst may be common to two light off catalysts,
forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system for
a specific vehicle, refer to the Exhaust System.
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 NOx. 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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4337
the engine configuration and number of cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Heated Oxygen Sensors (HO2S)
The HO2S provide the powertrain control module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how
the HO2S operates.)
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4338
Catalytic Converter: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4343
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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4344
Canister Purge Control Valve: Description and Operation
EVAP CANISTER PURGE VALVE
EVAP Canister Purge Valve
EVAP Canister Purge Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4345
Electronic EVAP Canister Purge Valve
The EVAP canister purge valve (Figure 100) and (Figure 101) is part of the Enhanced EVAP
system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the
EVAP canister to the intake manifold during various engine operating modes. The EVAP canister
purge valve is normally closed valve. The electronic EVAP canister purge valve (Figure 102)
controls the flow of vapors electronically by way of a solenoid thereby, eliminating the need for an
electronic vacuum regulator and vacuum diaphragm.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4346
Canister Purge Control Valve: Service and Repair
EVAPORATIVE EMISSION CANISTER AND PURGE VALVE
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist.
3. To remove individual components, only carry out the listed steps.
Illustration 1 Of 2
4. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 4347
Illustration 2 Of 2
5. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.
Item 6: Fuel Tank Removal Note
1. Remove the fuel tank.
INSTALLATION
1. To install, reverse the removal procedure. 2. Leak test the evaporative emission system. 3. Carry
out the evaporative emission repair drive cycle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service Precautions
Evaporative Canister Filter: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service Precautions > Page 4351
Evaporative Canister Filter: Service and Repair
DUST SEPARATOR
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist. 3. Remove the evaporative (EVAP) canister
solenoid.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Leak test the evaporative emission system. 3. Carry
out the evaporative emission repair drive cycle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Diagrams > Page 4359
Leak Detection Valve: Description and Operation
CANISTER VENT SOLENOID
Canister Vent (CV) Solenoid
During the Enhanced EVAP System test monitor, the canister vent (CV) solenoid (Figure 105)
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Service Precautions
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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Service Precautions > Page 4363
Liquid Vapor Separator: Service and Repair
FUEL VAPOR VENT VALVE
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
Disconnect the battery ground cable.
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Leak test the evaporative emission system. 3. Carry
out the evaporative emission repair drive cycle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Refueling Vapor Recovery System > System Information > Description and Operation
Refueling Vapor Recovery System: Description and Operation
ON-BOARD REFUELING VAPOR RECOVERY (ORVR) EVAPORATIVE EMISSION (EVAP)
SYSTEM
On-Board Refueling Vapor Recovery Evaporative Emission System
On-Board Refueling Vapor Recovery Evaporative Emission System
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Refueling Vapor Recovery System > System Information > Description and Operation > Page 4367
On-Board Refueling Vapor Recovery Evaporative Emission System
The basic elements forming the ORVR system (Figure 107), (Figure 108) and (Figure 109)
operation are as follows when fuel is dispensed:
1. The fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank, while liquid is
entering the fuel tank (liquid in the one inch
diameter tube blocks vapors from rushing back up the fuel filler pipe).
2. A fuel vapor control valve controls the flow of vapors out of the fuel tank (valve closes when
liquid level reaches a height associated with
the fuel tank usable capacity). This valve accomplishes the following: a. Limits the total amount of
fuel that can be dispensed into the fuel tank. b. Prevents liquid gasoline from exiting the fuel tank
when submerged (and also when tipped well beyond a horizontal plane as part of the
vehicle roll-over protection in road accidents).
c. Minimizes vapor flow resistance during anticipated refueling conditions.
3. Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the fuel
tank vapors (displaced by the incoming
liquid) to the EVAP canister.
4. A check valve in the bottom of the fuel filler pipe prevents liquid from rushing back up the fuel
filler pipe during the liquid flow variations
associated with the filler nozzle shut-off.
Between refueling events, the EVAP canister is purged with fresh air so that it may be used again
to store vapors accumulated during engine soaks or subsequent refueling events. The vapors
drawn off of the carbon in the EVAP canister are consumed in the engine.
Refer to Evaporative Emissions System for information on the following Evaporative Emission
System components: liquid/vapor fuel discriminator, fuel filler pipe check valve, fill limit valve
assembly, fill limit vent valve assembly, fuel filler pipe flapper valve, fuel vapor control valve (fuel
tank mounted), ORVR T-connector assembly and EVAP canister.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4372
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
EGR VACUUM REGULATOR SOLENOID
EVR Solenoid
Test Graph
EGR Vacuum Regulator Solenoid Data Chart
The EGR Vacuum Regulator Solenoid (EVR), (Figure 90) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation
EGR Tube: Description and Operation
ORIFICE TUBE ASSEMBLY
Orifice Tube Assembly
The orifice tube assembly (Figure 92) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications
EGR Valve: Specifications
Exhaust Gas Recirculation (EGR) Valve Bolts
........................................................................................................................................ 20 Nm (15 ft.
lbs.) EGR Valve Tube ..........................................................................................................................
............................................................ 34 Nm (25 ft. lbs.) EGR Vacuum Regulator Solenoid Bolts
............................................................................................................................................... 10 Nm
(89 inch lbs.) Exhaust Gas Recirculation (EGR) Tube Bracket Bolts
......................................................................................................................... 10 Nm (89 inch lbs.)
EGR Valve Tube Fittings .....................................................................................................................
.................................................... 40 Nm (30 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 4379
EGR Valve: Description and Operation
EXHAUST GAS RECIRCULATION VALVE
EGR Valve
The EGR valve (Figure 91) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 4380
EGR Valve: Service and Repair
Exhaust Gas Recirculation (EGR) Valve
Removal and Installation
1. With the vehicle in NEUTRAL, position on a hoist. 2. Remove the air cleaner outlet tube.
3. To remove individual components, carry out only the listed steps.
Part 1 Of 2
Part 2 Of 2
4. Illustration 1 of 2. Remove the components in the order indicated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 4381
Part 1 Of 2
Part 2 Of 2
5. Illustration 2 of 2. Remove the components in the order indicated. 6. To install, reverse the
removal procedure.
Item 13: EGR Valve Gasket Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 4382
1. NOTE: The EGR valve sealing surfaces are soft metals.
Carefully clean the EGR sealing surfaces.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability
Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4387
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4388
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4389
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4390
Pressure Feedback Exhaust Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4391
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4392
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4393
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4394
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Service and Repair
Positive Crankcase Ventilation Valve: Service and Repair
Positive Crankcase Ventilation (PCV) Valve
1. Remove the components in the order indicated.
Part 1 Of 2
Part 2 Of 2
2. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4404
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4405
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4406
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4407
Pressure Feedback Exhaust Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4408
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4409
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4410
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 88) 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 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.
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4411
Tube Mounted Differential Pressure Feedback EGR Sensor
The tube mounted differential pressure feedback EGR sensor (Figure 89) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information > Page 4418
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 4419
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-R0087 OR EQUIVALENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 4420
Fuel Pressure Test Port: Service and Repair
FUEL PRESSURE RELIEF VALVE
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 4424
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 4425
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 4429
Accelerator Pedal: Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 4430
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions
Accelerator Pedal: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4433
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4434
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4435
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4436
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4437
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4438
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4439
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4440
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4441
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4442
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4443
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4444
Accelerator Pedal: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4445
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4446
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4447
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4448
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4449
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4450
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4451
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4452
Accelerator Pedal: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4453
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4454
Accelerator Pedal: Electrical Diagrams
Adjustable Pedal
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
127-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4455
127-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4456
127-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Diagram Information and Instructions > Page 4457
127-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Diagrams > Page 4458
Accelerator Pedal: Description and Operation
ACCELERATION CONTROL
The accelerator controls consist of:
- the adjustable accelerator and brake pedals assembly.
- the accelerator cable.
- the accelerator cable bracket.
The throttle is controlled by an accelerator cable which is routed through the accelerator cable
bracket and attached to the adjustable accelerator pedal and shaft assembly. The adjustable
accelerator pedal assembly allows both the accelerator and brake pedals to be adjusted
simultaneously forward or rearward. A rocker switch located on the instrument panel provides
adjustment on the pedal assembly when it is activated. The adjustable pedals can also be
controlled with the memory seat selection. The adjustable accelerator pedal and shaft assembly
can be serviced separately on the adjustable pedals assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
INSPECTION AND VERIFICATION
1. Verify the customer's concern by operating the acceleration control system to duplicate the
condition. 2. Inspect to determine if any of the following mechanical concerns apply.
VISUAL INSPECTION CHART
Mechanical Damaged accelerator pedal and shaft.
- Damaged linkage.
- Damaged accelerator cable.
- High engine idle speed. Damaged throttle body.
- Damaged or binding adjustable pedal assembly.
3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4.
If the concern remains after the inspection, determine the symptom(s) and go to the Symptom
Chart. See: Symptom Related Diagnostic
Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4461
Accelerator Pedal: Symptom Related Diagnostic Procedures
Symptom Chart, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4462
Symptom Chart, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Cable and Bracket
Accelerator Pedal: Service and Repair Accelerator Cable and Bracket
ACCELERATOR CABLE AND BRACKET - 4.OL SOHC
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Accelerator Cable Removal Note
1. Remove the accelerator cable from the rubber plunger.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Cable and Bracket > Page 4465
2. Position the rubber plunger rearward and remove the cable from the accelerator pedal.
3. Disconnect the accelerator cable from the throttle body.
4. Squeeze the tabs and remove the accelerator cable from the bracket.
5. Pull the accelerator cable boot to the unlock position and remove the accelerator cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Cable and Bracket > Page 4466
Accelerator Pedal: Service and Repair Accelerator Pedal and Shaft
ACCELERATOR PEDAL AND SHAFT
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Accelerator Cable Removal Note
1. Remove the accelerator cable from the rubber plunger.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Cable and Bracket > Page 4467
2. Position the rubber plunger rearward and remove the cable from the accelerator pedal.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C Underhood - Buzz or Flutter Noise
Air Cleaner Housing: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Customer Interest for Air Cleaner Housing: > 03-5-2 > Mar > 03 > A/C Underhood - Buzz or Flutter Noise > Page 4476
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 > Mar > 03 >
A/C - Underhood - Buzz or Flutter Noise
Air Cleaner Housing: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Housing: > 03-5-2 > Mar > 03 >
A/C - Underhood - Buzz or Flutter Noise > Page 4482
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Page 4483
Air Cleaner Housing: Service and Repair
AIR CLEANER ASSEMBLY
REMOVAL
1. Remove the splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Page 4484
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4488
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4489
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 4490
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Capacity Specifications
Fuel: Capacity Specifications
Fuel Capacity .......................................................................................................................................
........................................................ 22.5 gal (85.2L)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Capacity Specifications > Page 4495
Fuel: Fluid Type Specifications
Fuel Type .............................................................................................................................................
................................................................. 87 Octane
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cut Valve Solenoid (CNG) >
Component Information > Description and Operation
Fuel Cut Valve Solenoid (CNG): Description and Operation
NATURAL GAS FUEL SYSTEM
Fuel Tank Shutoff Valve
Fuel Tank Shutoff Valve
The fuel tank shutoff solenoid valve (Figure 84) is located in the fuel tank. The solenoid valves are
on the same circuit as the gasoline fuel pump and utilize the same Inertia fuel shutoff (IFS) switch
as gasoline. When the key is in the off position, the shutoff valves are closed and fuel in the tanks
is isolated. During refueling, the shutoff valve acts as a check valve and allows flow due to
pressure differential between the fuel being added from the fill station and the fuel in the tank.
The internal solenoid valves also have the capability of being "manually locked down." If, while
servicing the vehicle, it becomes necessary to remove the fuel tank, the lock down feature provides
an added measure of safety. In addition, the valve has an internal Canadian Gas Association
(CGA) type 9 fusible link Pressure Relief Device (PRD) that senses the internal fuel tank gas
temperature. The contents in the tank are vented when the internal fuel tank gas temperature
reaches 199°C (217°F) and melts the fusible link. The escaping gas is vented through a vent line to
the atmosphere.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Description and Operation > Gasoline Fuel System
Fuel Filler Cap: Description and Operation Gasoline Fuel System
FUEL FILLER CAP
Fuel Filler Cap
The fuel filler cap (Figure 106) is used to prevent fuel spill and close the evaporative emission/fuel
system to atmosphere. Some vehicles may have a Fuel Cap On 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.
Refer to the individual component for information on the following Evaporative Emission System
components: fuel vapor control valve, fuel vapor vent valve assembly and fuel vapor separator
assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Description and Operation > Gasoline Fuel System > Page 4503
Fuel Filler Cap: Description and Operation Natural Gas Fuel System
NATURAL GAS FUEL SYSTEM
Fueling Connector
Flange Assembly-Fuel Tank Fill
Flange Assembly
The flange assembly (Figure 83) is designed for 20,685 kPa (3,000 psi) service pressure and is the
refueling connection to fill the vehicle. The assembly is mounted behind the fuel filler door and
attached to the fuel filler housing, similar to a gasoline vehicle. This assembly consists of an
NGVP1 type receptacle with a 150 micron filter (which can be serviced), a spring loaded check
valve to allow filling of the vehicle and a manually opened bypass to provide safe venting of the fuel
system. The vehicle is refueled by attaching the fuel station fill nozzle to the receptacle and locking
into place.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 4508
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
EFI/CFI Fuel Pressure Gauge
SPECIAL 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.
2. NOTE: Drain the fuel into a suitable container.
Install the special tool and open the valve slowly to relieve the fuel pressure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 4509
EFI/CFI Fuel Pressure Gauge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1
Fuel Injector: Diagrams Fuel Injector 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4514
Fuel Injector: Diagrams Fuel Injector 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4515
Fuel Injector: Diagrams Fuel Injector 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4516
Fuel Injector: Diagrams Fuel Injector 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4517
Fuel Injector: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4518
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4519
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4520
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4521
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4522
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 4523
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service Precautions > Technician Safety Information
Fuel Injector: 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Service Precautions > Technician Safety Information > Page 4526
Fuel Injector: Vehicle Damage Warnings
CAUTION:
- 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.
- O-ring seals are made of special fuel-resistant material. Use of ordinary O-ring seals can cause
the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Gasoline Fuel System
Fuel Injector: Description and Operation Gasoline Fuel System
FUEL INJECTOR
Fuel Injectors
The fuel injector (Figure 71) is a solenoid-operated valve that meters fuel flow to the engine. The
fuel injector is opened and closed a constant number of times per crankshaft revolution. The
amount of fuel is controlled by the length of time the fuel injector is held open.
The fuel injector is normally closed and is operated by 12 volt VPWR from the electronic engine
control power relay. The ground signal is controlled by the PCM.
CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical connector
terminals. The solenoids may be damaged internally in a matter of seconds.
The injector is the Deposit Resistant Injection (DRI) type and does not have to be cleaned.
However, it can be flow checked and, if found outside of specification, the fuel injector should be
replaced.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Gasoline Fuel System > Page 4529
Fuel Injector: Description and Operation Natural Gas Fuel System
FUEL INJECTOR(S)
Fuel Injector
The fuel injector (Figure 79) is a solenoid-operated valve that meters fuel flow to the engine. The
fuel injector is opened and closed every other crankshaft revolution. The amount of fuel is
controlled by the length of time the fuel injector is held open.
The fuel injector is normally closed and is operated by 12 volt Vehicle Power (VPWR) from the
power relay. The ground signal is controlled by the PCM.
The fuel injectors are used to meter natural gas to each combustion cylinder. Although the natural
gas fuel injectors appear very similar to some gasoline fuel injectors, they are unique. Flow
capacity of these fuel injectors is 6 to 12 times as large as various gasoline fuel injectors. Electrical
resistance is much lower than typical gasoline fuel injectors (4.6 ohms as opposed to 14.5 ohms).
To accommodate this lower resistance, a fuel injector driver module is used to convert the PCM
fuel injector driver signal to the signal required by the fuel injector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Page 4530
Fuel Injector: Service and Repair
FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR
Special Tool(s)
SPECIAL TOOL(S)
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: 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.
REMOVAL
1. Release the fuel system pressure. 2. Remove the intake manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Page 4531
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Page 4532
Part 2
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 1: Fuel Hose Spring Lock Coupling Removal Note
1. Remove the safety clip.
2. Install the special tool.
3. Close and push the special tool into the open side of the cage.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Page 4533
4. Separate the fitting and remove the special tool.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel-resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do
not reuse the O-ring seals.
NOTE: Install new O-ring seals and lubricate them with clean engine oil.
- After connecting the fuel line fitting, pull on the fitting to make sure it is fully engaged. Install the
safety clip.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Description and Operation > Page 4534
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Gasoline Fuel System
Fuel Pressure Regulator: Description and Operation Gasoline Fuel System
FUEL PRESSURE REGULATOR
Fuel Pressure Regulator
The fuel pressure regulator (Figure 72) is attached to the fuel rail downstream of the fuel injectors.
It regulates fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief
valve. One side of the diaphragm senses fuel pressure and the other side is connected to the
intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm.
Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop
across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is
bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel
tank.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Description and Operation > Gasoline Fuel System > Page 4539
Fuel Pressure Regulator: Description and Operation Natural Gas Fuel System
FUEL PRESSURE REGULATOR
Fuel Pressure Regulator
The fuel pressure regulator (Figure 80) used in the Natural Gas fuel system is a single-stage
pressure reducing regulator which expands natural gas from storage pressures of 1,379 to 20,685
kPa (200 to 3,000 psig) to engine fuel injector pressures of 724 to 862 kPa (105 to 125 psig)
The regulator contains a pressure relief device, a 1,896 kPa (275 psig) check valve, which protects
the low pressure fuel system. The low pressure fuel system no longer must fulfill the design
requirements of the high pressure fuel system, therefore reducing cost, weight and complexity.
When gas expands, the fuel temperature drops significantly causing extreme cold temperatures
(-177°C or -160°F) that may damage synthetic fuel system components as well as cause water
vapor within the fuel to condense, freeze and plug the lines, valve and injectors. To prevent this,
engine coolant is routed through the fuel pressure regulator to warm the fuel before it expands.
The regulator has an internal thermostat to control the flow of engine coolant. This prevents
overheating and subsequent thinning of the fuel which may cause lean combustion. Outlet coolant
flow is restricted by the thermostat when it rises above approximately 82°C (100°F).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Technician Safety Information > Page 4544
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Page 4545
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-R0087 OR EQUIVALENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Page 4546
Fuel Pressure Test Port: Service and Repair
FUEL PRESSURE RELIEF VALVE
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 can be ignited. Failure
to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions can result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Technician Safety Information > Page 4551
Fuel Pressure Pulsation Damper: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Page 4552
Fuel Pressure Pulsation Damper: Description and Operation
FUEL RAIL PULSE DAMPER
Pulse Damper
The fuel rail pulse damper (Figure 73) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Page 4553
Fuel Pressure Pulsation Damper: Service and Repair
FUEL PULSE DAMPER
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4560
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 4561
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-R0087 OR EQUIVALENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 4562
Fuel Pressure Test Port: Service and Repair
FUEL PRESSURE RELIEF VALVE
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.
REMOVAL
1. Release the fuel system pressure.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do not
reuse the O-ring seals.
To install, reverse the removal procedure. Install a new O-ring seal and lubricate it with clean engine oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4566
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4567
Fuel Pump Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 4568
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Technician Safety Information > Page 4573
Fuel Rail: Vehicle Damage Warnings
CAUTION:
- 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.
- O-ring seals are made of special fuel-resistant material. Use of ordinary O-ring seals can cause
the fuel system to leak. Do not reuse the O-ring seals.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4574
Fuel Rail: Description and Operation
NATURAL GAS FUEL SYSTEM
Fuel Rail
Fuel Rail Components
The fuel rail (Figure 78) distributes low pressure fuel from the chassis supply line to each fuel
injector. Fuel pressure at the top of each fuel injector is maintained within 1% of the other fuel
injectors at all times; this is done with nearly symmetric flow paths. The fuel rail is also designed to
have minimal flow restriction by increasing the cross-sectional flow area and reducing the flow path
length. The fuel rail contains several other Parts In Assembly (PIA) components that perform
crucial functions. These include: Injection pressure sensor which 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.
- Engine fuel temperature sensor which 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.
- Low pressure solenoid shut-off valve which isolates the fuel rail from the upstream fuel system
when the engine is OFF. This minimizes the amount of fuel available to flow through the fuel
injectors when the engine is off or leak from a damaged fuel rail during and after a crash. The valve
is controlled by the PCM fuel shut-off valve circuit and contains an inertia switch. The valve is only
on for one second after a key-on or whenever CKP signals are being received by the PCM.
- schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This
valve is needed to relieve the pressure in the system before and during service. This valve could
also be used to monitor the pressure near the injectors during diagnostic procedures.
Fuel Rail Shut-Off Valve
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4575
Fuel Rail Shut-Off Valve
The fuel rail shut-off valve (Figure 86) is a normally closed solenoid actuated valve that opens
when (along with all of the tank valves) Pin 80 is grounded by the PCM. The valve isolates the fuel
injectors from fuel line pressure when the engine is off. Nominal resistance of the coil is 11 ohms.
The fuel rail shut-off valve is wired in parallel with the four tank valves.
Fuel Rail Valve Circuit Operation
When the key is turned to the ON position, the power relay is turned on. The power relay provides
power to the PCM and the control side of the fuel shut off valve relay. The relay provides voltage to
the fuel rail valve. If the ignition switch is not turned to the START position, the PCM will shut off
the fuel rail valve after one second. The PCM will open the valve (along with the four tank valves)
to provide fuel while cranking. The valve will remain open when the engine is running unless the
inertia fuel shut-off switch is "tripped."
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4576
Fuel Rail: Service and Repair
FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR
Special Tool(s)
SPECIAL TOOL(S)
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: 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.
REMOVAL
1. Release the fuel system pressure. 2. Remove the intake manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4577
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4578
Part 2
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 1: Fuel Hose Spring Lock Coupling Removal Note
1. Remove the safety clip.
2. Install the special tool.
3. Close and push the special tool into the open side of the cage.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4579
4. Separate the fitting and remove the special tool.
INSTALLATION
1. CAUTION: O-ring seals are made of special fuel-resistant material. Use of ordinary O-ring seals
can cause the fuel system to leak. Do
not reuse the O-ring seals.
NOTE: Install new O-ring seals and lubricate them with clean engine oil.
- After connecting the fuel line fitting, pull on the fitting to make sure it is fully engaged. Install the
safety clip.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 4580
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid >
Component Information > Description and Operation
Fuel Shut-off Solenoid: Description and Operation
NATURAL GAS FUEL SYSTEM
Fuel Rail Shut-Off Valve
Fuel Rail Shut-Off Valve
The fuel rail shut-off valve (Figure 86) is a normally closed solenoid actuated valve that opens
when (along with all of the tank valves) Pin 80 is grounded by the PCM. The valve isolates the fuel
injectors from fuel line pressure when the engine is off. Nominal resistance of the coil is 11 ohms.
The fuel rail shut-off valve is wired in parallel with the four tank valves.
Fuel Rail Valve Circuit Operation
When the key is turned to the ON position, the power relay is turned on. The power relay provides
power to the PCM and the control side of the fuel shut off valve relay. The relay provides voltage to
the fuel rail valve. If the ignition switch is not turned to the START position, the PCM will shut off
the fuel rail valve after one second. The PCM will open the valve (along with the four tank valves)
to provide fuel while cranking. The valve will remain open when the engine is running unless the
inertia fuel shut-off switch is "tripped."
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation
Fuel Supply Line: Description and Operation
NATURAL GAS FUEL SYSTEM
Fuel Lines and Fittings
Fuel Line Assembly
A fuel line assembly (Figure 82) consists of flexible hose and/or stainless steel seamless tubing,
end fittings and tube nuts. The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced
with a stainless steel wire braided covering. The fittings are inserted into the hose ends and
crimped into place. The stainless steel tubing contains end fittings which are brazed to the tube.
There are high pressure fuel lines that are identified by either 1/4-inch or 3/8-inch outer diameter
and a low pressure fuel line identified by a 1/2-inch outer diameter. The low pressure fuel line has a
quick-connect at one end for connection to the fuel rail. The other fittings used on the natural gas
vehicle to connect fuel components are SAE O-ring face seal tube fittings. There are two end
types: an O-ring face seal end and a straight thread end. On tee and elbow fittings, a washer and a
positionable nut are provided to aid in orientation of the fitting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Page 4587
Fuel Supply Line: Tools and Equipment
3/8" Fuel Line Remover
AST tool# 8013
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Page 4588
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Description and Operation > Page 4589
8107 - 7-Piece Line Disconnect Set
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions
Fuel Filler Hose: 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 can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions can result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4594
Fuel Filler Hose: Service and Repair
FUEL TANK AND FILLER PIPE
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
1. WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel related component. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions can result in personal injury.
Disconnect the battery ground cable.
2. Release the fuel system pressure. 3. With the vehicle in NEUTRAL, position on a hoist. 4.
Evacuate the fuel tank. 5. Remove the driveshaft. 6. If equipped, remove the fuel tank skid plate.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4595
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4596
Part 2
7. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 4: Push Connect Fitting Removal Note
1. Remove the fuel filter shield.
1 Remove the nuts.
2 Remove the shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4597
2. Disconnect the safety clip.
3. Install the special tool and push it into the fitting.
4. Separate the fittings.
- Inspect for damage.
- Clean the fittings.
5. Remove the fuel filter.
1 Disconnect the fuel tubes.
2 Remove the filter.
Item 6: Clamp Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4598
1. Disconnect the fuel filler hose from the fuel filler intermediate pipe.
2. Using the special tool, siphon the fuel through the fuel filler hose.
Item 7: Fuel Tank Removal Note
1. Use a suitable jack to support the fuel tank.
Item 14: Fuel Filler Pipe Removal Note
1. Slightly lower the fuel tank.
Items 18 and 19: Quick Connect Fitting Removal Note
1. Unclip the tab.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4599
2. Depress the tabs and press the clip downward.
3. Separate the fittings.
Item 20: Fuel Pump Lock Ring Removal Note
1. Install the special tool.
Item 4: Push Connect Fitting Installation Note
1. NOTE: Lubricate the fuel fitting with clean engine oil.
Align the fuel line fitting and press together until a click is heard. Pull on the fitting to make sure it is fully engaged, then install the safety clip.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service Precautions > Page 4600
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4609
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4610
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4611
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4612
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4613
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4614
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4620
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4621
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4622
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4623
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4624
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 >
Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 4625
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Fuel Tank Unit: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams > Page 4629
Fuel Tank Unit: Description and Operation
FUEL PUMP MODULE
Fuel Pump Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams > Page 4630
Mechanical Returnless Fuel Pump Module (FPM)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams > Page 4631
Electronic Returnless Fuel Pump Module (FPM)
The fuel pump (FP) module (Figure 68),(Figure 69) and (Figure 70) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 4635
Idle Speed/Throttle Actuator - Electronic: 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 122) and (Figure 123) controls engine idle speed
and provides a dash pot 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 4636
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 124) 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
are 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 dash pot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 4637
Idle Speed/Throttle Actuator - Electronic: Service and Repair
IDLE AIR CONTROL (IAC) VALVE
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
View 151-20
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 4641
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Description and Operation > Gasoline Fuel System
Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System
The Inertia Fuel Shutoff (IFS) switch (Figure 73) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Description and Operation > Gasoline Fuel System > Page 4644
Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System
NATURAL GAS FUEL SYSTEM
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves.
The purpose of the IFS switch is to close the fuel shut-off valves if a crash 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 closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset
before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner
Guide for the location of the IFS.
Reset Instructions
1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak
is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner
Guide).
NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch)
against a spring.
4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking
natural gas.
WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO
NOT RESET THE IFS SWITCH.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Description and Operation > Page 4645
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4649
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4650
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4651
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4656
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4657
Fuel Pump Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4658
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4662
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4663
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4664
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4669
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4670
Air Flow Meter/Sensor: Service Precautions
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4671
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
serviced as a unit. Do not tamper with
the sensing elements located in the air flow bypass of the MAF body.
Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
View 151-20
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4675
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline
Fuel System
Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System
The Inertia Fuel Shutoff (IFS) switch (Figure 73) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Gasoline
Fuel System > Page 4678
Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System
NATURAL GAS FUEL SYSTEM
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The inertia fuel shutoff (IFS) switch (Figure 85) is used in conjunction with electric fuel close valves.
The purpose of the IFS switch is to close the fuel shut-off valves if a crash 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 closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset
before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner
Guide for the location of the IFS.
Reset Instructions
1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. If no natural gas leak
is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner
Guide).
NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch)
against a spring.
4. Turn key to on or start position for a few seconds, then off again. 5. Again, check for leaking
natural gas.
WARNING: IF YOU SMELL NATURAL GAS AT ANY TIME OTHER THAN DURING FUELING, DO
NOT RESET THE IFS SWITCH.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation > Page 4679
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4683
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4684
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4685
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4686
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Technician Safety Information > Page 4691
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Page 4692
Throttle Body: Description and Operation
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 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Page 4693
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The idle air control (IAC) valve assembly (Figure 122) and (Figure 123) controls engine idle speed
and provides a dash pot 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 124) 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
are correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control: ^
No touch start
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Page 4694
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dash pot 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.
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, EVAP and miscellaneous control signals (some vehicles only). 5. PCV air return (if
applicable). 6. A throttle body-mounted throttle position (TP) sensor.
Attention Decal Locations
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
121) advising not to clean.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Page 4695
Throttle Body: Service and Repair
THROTTLE BODY
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.
REMOVAL
1. Remove the air cleaner outlet tube.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications
Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 4699
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 4700
Throttle Cable/Linkage: Description and Operation
ACCELERATION CONTROL
The accelerator controls consist of:
- the adjustable accelerator and brake pedals assembly.
- the accelerator cable.
- the accelerator cable bracket.
The throttle is controlled by an accelerator cable which is routed through the accelerator cable
bracket and attached to the adjustable accelerator pedal and shaft assembly. The adjustable
accelerator pedal assembly allows both the accelerator and brake pedals to be adjusted
simultaneously forward or rearward. A rocker switch located on the instrument panel provides
adjustment on the pedal assembly when it is activated. The adjustable pedals can also be
controlled with the memory seat selection. The adjustable accelerator pedal and shaft assembly
can be serviced separately on the adjustable pedals assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
INSPECTION AND VERIFICATION
1. Verify the customer's concern by operating the acceleration control system to duplicate the
condition. 2. Inspect to determine if any of the following mechanical concerns apply.
VISUAL INSPECTION CHART
Mechanical Damaged accelerator pedal and shaft.
- Damaged linkage.
- Damaged accelerator cable.
- High engine idle speed. Damaged throttle body.
- Damaged or binding adjustable pedal assembly.
3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4.
If the concern remains after the inspection, determine the symptom(s) and go to the Symptom
Chart. See: Symptom Related Diagnostic
Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4703
Throttle Cable/Linkage: Symptom Related Diagnostic Procedures
Symptom Chart, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4704
Symptom Chart, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Page 4705
Throttle Cable/Linkage: Service and Repair
ACCELERATOR CABLE AND BRACKET - 4.OL SOHC
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Accelerator Cable Removal Note
1. Remove the accelerator cable from the rubber plunger.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Page 4706
2. Position the rubber plunger rearward and remove the cable from the accelerator pedal.
3. Disconnect the accelerator cable from the throttle body.
4. Squeeze the tabs and remove the accelerator cable from the bracket.
5. Pull the accelerator cable boot to the unlock position and remove the accelerator cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations
Throttle Position Sensor: Locations
View 151-75
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 4710
View 151-76
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 4711
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 4712
Throttle Position Sensor: Description and Operation
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 4713
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
REMOVAL
1. Disconnect the battery ground strap.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications > Page 4718
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators >
System Information > Specifications
Timing Marks and Indicators: Specifications
Ignition Timing .....................................................................................................................................
................................................................ 10° BTDC
NOTE: Base timing only.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations
Camshaft Position Sensor: Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 4729
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 4730
Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 4731
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Page 4732
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
View 151-8
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 4736
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 4737
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 4738
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions
Ignition Cable: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 4742
Ignition Cable: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 4743
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 4744
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 4745
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4750
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4751
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4752
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4753
Ignition Coil: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4754
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4755
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4756
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil on Plug (CoP) #1 > Page 4757
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4758
Ignition Coil: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4759
Ignition Coil: Description and Operation
COIL PACK
Horizontal Connector Six Tower Coil Pack
Series 5 Six Tower Coil Pack
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4760
Four-Tower Coil Packs
Series 5 Four Tower Coil Pack
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4761
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 58) and (Figure 59). For four-tower coil pack (four cylinder) applications the matched pairs
are 1 and 4, and 2 and 3 (Figure 60) and (Figure 61).
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4762
Ignition Coil: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4763
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4764
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 4765
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information >
Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information >
Locations > Page 4769
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor: Locations
View 151-55
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4773
View 151-77
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4774
Knock Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4775
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Relay > Component Information > Locations > Page 4780
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
View 151-73
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 4785
View 151-78
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 4786
Camshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 4787
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
Camshaft Position (CMP) Sensor
The camshaft position sensor (Figure 57) used by COP Integrated EI system is a magnetic
transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on
the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI
system uses this information to synchronize the firing of the individual coils.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Page 4788
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
View 151-8
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 4792
Crankshaft Position Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 4793
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION SENSOR
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor (Figure 56) is a magnetic transducer mounted on the engine
block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted
pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel
has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L
ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a
missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position
and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to
identify piston travel in order to synchronize the ignition system and provide a way of tracking the
angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor
configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by
measuring rapid decelerations between teeth.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 4794
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. NOTE: Be sure the sensor wiring is routed away from the battery cable.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Component Information > Diagrams > Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Component Information > Diagrams > Page 4800
Ignition Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Component Information > Diagrams > Page 4801
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Component Information > Diagrams > Page 4802
Ignition Switch: Service and Repair
IGNITION LOCK CYLINDER
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Ignition Lock Cylinder Removal Note
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations
Knock Sensor: Locations
View 151-55
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4806
View 151-77
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4807
Knock Sensor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4808
Knock Sensor: Service and Repair
KNOCK SENSOR (KS)
REMOVAL
1. Remove the intake manifold.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
Spark Plug: Specifications
Spark Plug
Refer to Vehicle Emissions Control Information (VECI) decal for spark plug information.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4812
Spark Plug: Service Precautions
CAUTION:
- It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
- Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
- Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4813
Spark Plug: Service and Repair
IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG
Remover, Spark Plug Wire
SPECIAL TOOL(S)
REMOVAL
1. Disconnect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4814
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4815
Part 2
2. NOTE: Use compressed air to remove any foreign material in the spark plug well before
removing the spark plug.
Remove the components in the order listed in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Spark Plug Wire Removal Note
1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid
possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug
wire locations before removing them.
Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
Item 5: Spark Plug Wire-to-Spark Plug Removal Note
1. 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.
With a twisting motion, use the special tool to pull the spark plug wire from the spark plug.
INSTALLATION
1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact
the exhaust manifold.
NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots and the
spark plug.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4816
Remover, Spark Plug Wire
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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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 4825
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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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 4826
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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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 4827
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4828
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4829
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4830
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4831
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4832
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4833
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4834
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4835
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4836
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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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 4837
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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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 4838
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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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 4839
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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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 4840
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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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 4841
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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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 4842
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 4843
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4844
Pressure Regulating Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4845
29-3
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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 4846
Pressure Regulating Solenoid: Description and Operation
Pressure Control Solenoids (PCA, PCB, PCC)
The pressure control (PC) solenoids are a variable-force style (VFS) solenoid. The VFS-type
solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off
while verifying the output from the other solenoid. The second pressure tap is used to verify the
output from the PC C solenoid.
There are three PC solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
The powertrain control module (PCM) varies the current to the PC solenoid.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
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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 4847
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4848
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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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 4849
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair
Shift Interlock Solenoid: Service and Repair
Removal and Installation
NOTE: Some 2002-2005 Explorer 4 Dr/Mountaineer vehicles may require a greater effort to move
the gear selector lever from drive to park. This may be due to a time delay with the brake shift
interlock pin retraction.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 fasteners supporting the instrument panel knee bolster from below the steering
column and remove the cover.
3. Remove the 3 fasteners supporting the steering column lower shroud and remove the cover.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair > Page 4853
4. Remove the 3 wiring bundle carrier fasteners from the bottom of the steering column to allow
movement while removing the brake shift interlock
switch. It may be necessary to release the connectors from the multifunction switch.
5. Remove the brake shift interlock bolts.
6. Pull the brake shift interlock tab on the bottom of the column downward to help free the brake
shift interlock from the column housing.
7. Break the 2 side tabs off the brake shift interlock by the white wiring connector.
8. Push the locking tab on the white connector towards the wiring to release the connector from the
brake shift interlock. Be careful not to damage
the connector or wiring. If the connector does not free easily, a very small flat screwdriver may be
used to help lift the locking tab.
9. Connect the wiring to the new brake shift interlock. Make sure all clips are fully engaged to
prevent the connector from pulling free.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair > Page 4854
10. Position the brake shift interlock onto the steering column and reinstall fasteners.
11. Check brake shift interlock function. With the key in the accessory or run position, press the
brake pedal. The brake shift interlock pin should
retract on brake application and spring up 1 second after releasing the brake pedal. Repeat several
times.
12. Reinstall the fasteners to connect the wiring bundle carrier to the steering column. Make sure
all connections to the multifunction switch unit are
secured correctly.
13. Assemble the steering column in reverse order. Make sure the rubber gap hider around the
shift lever is correctly seated on the shroud.
14. Cycle the shift lever from park to drive and drive back to park several times to verify improved
shift effort.
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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
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 > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring 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 4860
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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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 4861
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4862
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4863
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4864
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4865
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4866
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4867
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4868
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4869
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4870
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4871
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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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 4872
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4873
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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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 4874
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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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 4875
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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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 4876
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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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 4877
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 4878
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4879
Shift Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4880
29-3
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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 4881
Shift Solenoid: Description and Operation
Shift Solenoids (SSA, SSB, SSC, SSD)
Four On/Off shift solenoids allow the powertrain control module (PCM) to control shift scheduling.
The solenoids are three-way, normally open style. The shift solenoids SSA, SSB, SSC, and SSD
provide gear selection of first through fifth and reverse gears by directing PC pressures to the
appropriate elements. Coast braking and manual gears are also controlled by the shift solenoids.
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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 4882
Shift Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
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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 4883
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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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 4884
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
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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 > Locations
Torque Converter Clutch 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 > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4890
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Information > Diagrams > Diagram Information and Instructions > Page 4891
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Information > Diagrams > Diagram Information and Instructions > Page 4892
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Information > Diagrams > Diagram Information and Instructions > Page 4893
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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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 4895
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
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Symbols Part 2
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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 4897
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4898
Symbols Part 4
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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 4899
Symbols Part 5
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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 4900
Systems Overview
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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 4901
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 4902
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Information > Diagrams > Diagram Information and Instructions > Page 4903
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Information > Diagrams > Diagram Information and Instructions > Page 4904
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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Information > Diagrams > Diagram Information and Instructions > Page 4905
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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Information > Diagrams > Diagram Information and Instructions > Page 4906
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Information > Diagrams > Diagram Information and Instructions > Page 4907
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 4908
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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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 4909
Torque Converter Clutch Solenoid: Exploded Views
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Information > Diagrams > Diagram Information and Instructions > Page 4910
29-3
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Information > Diagrams > Page 4911
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is a pulse width modulating type solenoid which is used
to control the apply and release of the TCC.
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Information > Diagrams > Page 4912
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
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Information > Diagrams > Page 4913
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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Information > Diagrams > Page 4914
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
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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 >
Technical Service Bulletins > Customer Interest: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: Customer Interest A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
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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 >
Technical Service Bulletins > All Technical Service Bulletins: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and
3rd Gear
Control Module: All Technical Service Bulletins A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
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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 >
Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle
Hub Bearing Noise
Wheel Bearing: All Technical Service Bulletins Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
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Hub Bearing Noise > Page 4940
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
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Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle
Hub Bearing Noise > Page 4941
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
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Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle
Hub Bearing Noise > Page 4942
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
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and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle
Hub Bearing Noise > Page 4948
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 >
Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle
Hub Bearing Noise > Page 4949
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 >
Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle
Hub Bearing Noise > Page 4950
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 >
Technical Service Bulletins > Page 4951
View 151-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 >
Technical Service Bulletins > Page 4952
Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams
Overdrive Switch: Diagrams
Transmission Control Switch (TCS) C/O
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > Page 4961
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4965
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4966
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4967
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4968
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Speed sensor screws ..........................................................................................................................
....................................................... 14 Nm (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 4974
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 4975
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed Sensor > Page 4978
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed Sensor > Page 4979
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 4982
1. Remove the OSS sensor.
1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the OSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 4983
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 4984
1. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the transmission.
^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the TSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 4985
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 4986
1. Remove the intermediate shaft speed sensor.
1 Remove the intermediate shaft speed sensor screw.
2 Remove the intermediate shaft speed sensor from the transmission.
^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the intermediate shaft speed sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 solenoid body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4992
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4993
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4994
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4995
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4996
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4997
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4998
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 4999
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5000
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5001
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5002
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5003
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5004
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5005
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5006
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5007
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5008
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5009
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5010
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5011
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5012
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 solenoid body. - The PCM uses the TFT signal to help determine shift
scheduling, torque converter clutch operation and pressure control requirements.
It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature.
The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift
schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits
torque converter clutch (TCC) operation at low transmission fluid temperatures and use to
determine pressure control (PC) solenoid operations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 5017
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 05-13-13 > Jul > 05 > Engine Controls - Hard or No Start
After Short Hot Soak
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard or No Start
After Short Hot Soak
TSB 05-13-13
07/11/05
HARD START/NO START CONDITION DURING COLD AMBIENT TEMPERATURES AFTER
SHORT HOT SOAK PERIOD - 4.0L ENGINE
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer/Mountaineer vehicles equipped with the 4.0L engine, may exhibit
a hard start/no start condition during cold ambient temperatures after a short hot soak period.
ACTION Reprogram the powertrain control module (PCM) to the latest calibration level using WDS
release B37.12 and higher or B38.2 and higher. This new calibration is not included in the B38 CD.
Calibration files may also be obtained at the website. If the concern is not resolved, perform normal
diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051313A 2002-2003 0.4 Hr.
Explorer/Mountaineer 4.0L SOHC: Check For Diagnostic Trouble Codes And Reprogram The
Powertrain Control Module (Do Not Use With 12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
05-13-13 > Jul > 05 > Engine Controls - Hard or No Start After Short Hot Soak
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard
or No Start After Short Hot Soak
TSB 05-13-13
07/11/05
HARD START/NO START CONDITION DURING COLD AMBIENT TEMPERATURES AFTER
SHORT HOT SOAK PERIOD - 4.0L ENGINE
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer/Mountaineer vehicles equipped with the 4.0L engine, may exhibit
a hard start/no start condition during cold ambient temperatures after a short hot soak period.
ACTION Reprogram the powertrain control module (PCM) to the latest calibration level using WDS
release B37.12 and higher or B38.2 and higher. This new calibration is not included in the B38 CD.
Calibration files may also be obtained at the website. If the concern is not resolved, perform normal
diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051313A 2002-2003 0.4 Hr.
Explorer/Mountaineer 4.0L SOHC: Check For Diagnostic Trouble Codes And Reprogram The
Powertrain Control Module (Do Not Use With 12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5035
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5036
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5042
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5043
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5052
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5053
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5054
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5055
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5056
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5057
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5058
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5059
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5060
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5061
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5062
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5063
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5064
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5065
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5066
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5067
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5068
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5069
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5070
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5071
Pressure Regulating Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5072
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5073
Pressure Regulating Solenoid: Description and Operation
Pressure Control Solenoids (PCA, PCB, PCC)
The pressure control (PC) solenoids are a variable-force style (VFS) solenoid. The VFS-type
solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off
while verifying the output from the other solenoid. The second pressure tap is used to verify the
output from the PC C solenoid.
There are three PC solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
The powertrain control module (PCM) varies the current to the PC solenoid.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5074
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5075
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5076
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair
Shift Interlock Solenoid: Service and Repair
Removal and Installation
NOTE: Some 2002-2005 Explorer 4 Dr/Mountaineer vehicles may require a greater effort to move
the gear selector lever from drive to park. This may be due to a time delay with the brake shift
interlock pin retraction.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 fasteners supporting the instrument panel knee bolster from below the steering
column and remove the cover.
3. Remove the 3 fasteners supporting the steering column lower shroud and remove the cover.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5080
4. Remove the 3 wiring bundle carrier fasteners from the bottom of the steering column to allow
movement while removing the brake shift interlock
switch. It may be necessary to release the connectors from the multifunction switch.
5. Remove the brake shift interlock bolts.
6. Pull the brake shift interlock tab on the bottom of the column downward to help free the brake
shift interlock from the column housing.
7. Break the 2 side tabs off the brake shift interlock by the white wiring connector.
8. Push the locking tab on the white connector towards the wiring to release the connector from the
brake shift interlock. Be careful not to damage
the connector or wiring. If the connector does not free easily, a very small flat screwdriver may be
used to help lift the locking tab.
9. Connect the wiring to the new brake shift interlock. Make sure all clips are fully engaged to
prevent the connector from pulling free.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 5081
10. Position the brake shift interlock onto the steering column and reinstall fasteners.
11. Check brake shift interlock function. With the key in the accessory or run position, press the
brake pedal. The brake shift interlock pin should
retract on brake application and spring up 1 second after releasing the brake pedal. Repeat several
times.
12. Reinstall the fasteners to connect the wiring bundle carrier to the steering column. Make sure
all connections to the multifunction switch unit are
secured correctly.
13. Assemble the steering column in reverse order. Make sure the rubber gap hider around the
shift lever is correctly seated on the shroud.
14. Cycle the shift lever from park to drive and drive back to park several times to verify improved
shift effort.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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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 5087
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5088
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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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 5089
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5090
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5091
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5092
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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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 5093
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5094
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5095
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5096
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5097
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5098
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5099
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5100
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5101
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5102
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5103
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5104
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5105
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5106
Shift Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5107
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5108
Shift Solenoid: Description and Operation
Shift Solenoids (SSA, SSB, SSC, SSD)
Four On/Off shift solenoids allow the powertrain control module (PCM) to control shift scheduling.
The solenoids are three-way, normally open style. The shift solenoids SSA, SSB, SSC, and SSD
provide gear selection of first through fifth and reverse gears by directing PC pressures to the
appropriate elements. Coast braking and manual gears are also controlled by the shift solenoids.
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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 5109
Shift Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5110
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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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 5111
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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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 5117
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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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 5118
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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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 5119
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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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 5120
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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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 5121
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5122
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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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 5123
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5124
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5125
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5126
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5127
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5128
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5129
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5130
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5131
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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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 5132
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5133
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5134
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 5135
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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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 5136
Torque Converter Clutch Solenoid: Exploded Views
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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 5137
29-3
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5138
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is a pulse width modulating type solenoid which is used
to control the apply and release of the TCC.
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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 > Page 5139
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5140
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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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 > Page 5141
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
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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
Pressure Regulating Solenoid: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Page 5149
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Page 5150
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Page 5151
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Page 5152
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Page 5153
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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Page 5154
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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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 5155
Symbols Part 2
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Page 5156
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5157
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5158
Symbols Part 5
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Page 5159
Systems Overview
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Page 5160
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Page 5161
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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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 5162
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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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 5163
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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Page 5164
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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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 5165
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Page 5166
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 5167
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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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 5168
Pressure Regulating Solenoid: Exploded Views
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Page 5169
29-3
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Pressure Regulating Solenoid: Description and Operation
Pressure Control Solenoids (PCA, PCB, PCC)
The pressure control (PC) solenoids are a variable-force style (VFS) solenoid. The VFS-type
solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off
while verifying the output from the other solenoid. The second pressure tap is used to verify the
output from the PC C solenoid.
There are three PC solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
The powertrain control module (PCM) varies the current to the PC solenoid.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
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Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair
Shift Interlock Solenoid: Service and Repair
Removal and Installation
NOTE: Some 2002-2005 Explorer 4 Dr/Mountaineer vehicles may require a greater effort to move
the gear selector lever from drive to park. This may be due to a time delay with the brake shift
interlock pin retraction.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 fasteners supporting the instrument panel knee bolster from below the steering
column and remove the cover.
3. Remove the 3 fasteners supporting the steering column lower shroud and remove the cover.
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4. Remove the 3 wiring bundle carrier fasteners from the bottom of the steering column to allow
movement while removing the brake shift interlock
switch. It may be necessary to release the connectors from the multifunction switch.
5. Remove the brake shift interlock bolts.
6. Pull the brake shift interlock tab on the bottom of the column downward to help free the brake
shift interlock from the column housing.
7. Break the 2 side tabs off the brake shift interlock by the white wiring connector.
8. Push the locking tab on the white connector towards the wiring to release the connector from the
brake shift interlock. Be careful not to damage
the connector or wiring. If the connector does not free easily, a very small flat screwdriver may be
used to help lift the locking tab.
9. Connect the wiring to the new brake shift interlock. Make sure all clips are fully engaged to
prevent the connector from pulling free.
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10. Position the brake shift interlock onto the steering column and reinstall fasteners.
11. Check brake shift interlock function. With the key in the accessory or run position, press the
brake pedal. The brake shift interlock pin should
retract on brake application and spring up 1 second after releasing the brake pedal. Repeat several
times.
12. Reinstall the fasteners to connect the wiring bundle carrier to the steering column. Make sure
all connections to the multifunction switch unit are
secured correctly.
13. Assemble the steering column in reverse order. Make sure the rubber gap hider around the
shift lever is correctly seated on the shroud.
14. Cycle the shift lever from park to drive and drive back to park several times to verify improved
shift effort.
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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 > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5185
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5186
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5188
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5189
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5190
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5191
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5192
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5193
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5194
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5195
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5196
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5197
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5198
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5199
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5200
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5201
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5202
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5203
Shift Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5204
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5205
Shift Solenoid: Description and Operation
Shift Solenoids (SSA, SSB, SSC, SSD)
Four On/Off shift solenoids allow the powertrain control module (PCM) to control shift scheduling.
The solenoids are three-way, normally open style. The shift solenoids SSA, SSB, SSC, and SSD
provide gear selection of first through fifth and reverse gears by directing PC pressures to the
appropriate elements. Coast braking and manual gears are also controlled by the shift solenoids.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5206
Shift Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5207
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5208
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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> Page 5214
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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> Page 5215
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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> Page 5216
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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> Page 5217
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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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 5218
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5219
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5220
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5221
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5222
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5223
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5224
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5225
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5226
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5227
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5228
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5229
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5230
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5231
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5232
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5233
Torque Converter Clutch Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5234
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5235
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is a pulse width modulating type solenoid which is used
to control the apply and release of the TCC.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5236
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5237
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5238
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
Band Apply Servo: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5247
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5248
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5249
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5250
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
Band Apply Servo: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5256
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5257
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5258
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 5259
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Page 5260
Band Apply Servo: Service and Repair
Reverse Servo Assembly
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
1. With the vehicle in PARK, position on a hoist. 2. Remove the components in the order indicated
in the illustration and table.
3. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Page 5261
4. Partially fill the transmission.
Item 5: Reverse Servo Screws Installation Note
1. Install the reverse servo. Tighten the screws in the sequence shown in two stages.
^ Stage 1: Tighten screws to 5 Nm(44 inch lbs.)
^ Stage 2: Tighten screws to 11 Nm (8 ft. lbs.)
Item 3: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket, and loosely install the screws.
Item 2: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set
Case: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 5270
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 5271
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 5272
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 5273
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set
Case: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 5279
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 5280
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 5281
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 5282
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Page 5283
Case: Specifications
Case-to-center support bolt .................................................................................................................
........................................................ 11 Nm (8 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications
Clutch: Specifications
Clutch coil assembly nuts ....................................................................................................................
.................................................. 10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Drain Plug, A/T >
Component Information > Specifications
Drain Plug: Specifications
Drain plug ............................................................................................................................................
..................................................... 15 Nm (11 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fill Plug, A/T > Component
Information > Specifications
Fill Plug: Specifications
Fill plug ................................................................................................................................................
.................................................... 15 Nm (11 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
......................................................... 12.7 qts (12.0L)
Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler
size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should
be checked by a qualified technician.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 5297
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Type ...............................................................................................................................................
Motorcraft MERCON V Automatic Transmission Fluid
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment
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 specified for this transmission. Do not use
supplemental transmission fluid additives, treatments or clean agents. The use of these materials
may affect transmission operation and result in damage to internal transmission components.
CAUTION: Always refer to the instructions supplied with the 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 line. This will
help remove any foreign material trapped in the fluid coolers.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5300
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5301
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5302
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5303
Fluid - A/T: Service and Repair Transmission Fluid Level Check
Transmission Fluid Level Check
NOTE: This drain and fill procedure is referenced from TSB # 02-20-3 and applies to 5R55N,
5R55S, and 5R55W Automatic Transmissions.
Part 2 Of 2
Special Tool(s)
Fluid Fill Reference
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5304
NOTE: Left side of case is shown.
1. Using the scan tool (WDS), monitor the Transmission Fluid Temperature (TFT) using PID TFT.
2. Start the vehicle.
3. NOTE: Engine idle speed is approximately 650 rpm.
While proceeding with this procedure, run the engine until the transmission fluid temperature is
between 27°C - 49°C (80°F - 120°F).
4. Move the range selector lever slowly through each gear, stopping in each position and allowing
the transmission to engage. 5. Place the range selector lever in the PARK position. 6. With the
engine running, position the vehicle on a hoist and set it as close to level as possible.
7. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug
using a 3/16-inch Allen key.
8. Install the special tool into the pan.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5305
9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is
clean.
Fill the special tool with clean automatic transmission fluid.
10. Hang the special tool under the vehicle. Position it upright and close to the transmission.
11. Connect the special tools.
^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid
Level and Fill Plug Adapter at the bottom of the transmission fluid pan.
12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from
the special tool. Fluid will immediately start flowing
out of the special tool into the transmission fluid pan.
13. Add one pint of transmission fluid into the fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the end of the
hose.
14. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the
transmission is full. If no fluid drains back, more fluid will
need to be added. Repeat steps 12 and 13.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Drain and Refill W/Automated Equipment > Page 5306
15. Once the transmission is full, place a hand vacuum pump on the open end of the
vacuum/pressure hose of the special tool and apply vacuum to the
system. This will pull out any extra fluid trapped in the system and direct it into the container.
16. Allow the fluid to drain. Make sure that the fluid temperature is between 27°C - 49°C (80°F 120°F). When the fluid comes out as a thin stream
or drip, the fluid is at the correct level.
17. Reinstall the small (center) fluid level indicating plug using a 3/16 inch Allen key. 18. Check the
operation of the transmission by moving the range selector lever slowly through each gear,
stopping in each position and allowing the
transmission to engage.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Mechanical Specifications
Fluid Filter - A/T: Mechanical Specifications
Transmission fluid filter screws
............................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Mechanical Specifications > Page 5311
Fluid Filter - A/T: Fluid Type Specifications
Fluid Filter Kit .......................................................................................................................................
................................................... XC3Z-7B I55-AA
Fluid Filter ............................................................................................................................................
..................................................... XC3Z-7B155-BA
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5312
Fluid Filter - A/T: Service and Repair
Fluid Pan, Gasket and Filter
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
NOTE: Install a new transmission fluid filter.
1. With the vehicle in PARK, position on a hoist. 2. Remove the components in the order indicated
in the illustration and table.
3. To install, reverse the removal procedure. 4. Partially fill the transmission.
Item 6: Transmission Fluid Pan Filter Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5313
1. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly sealed on the filter.
Lubricate the seals and install the transmission fluid filter.
Item 3: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Item 2: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications
Fluid Pan: Specifications
Fluid pan drain plug .............................................................................................................................
..................................................... 26 Nm (19 ft. lbs.) Transmission fluid pan-to-case screws
....................................................................................................................................................... 11
Nm (8 ft. lbs.)
NOTE: Tighten the transmission fluid pan screws in a crisscross sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 5317
Fluid Pan: Service and Repair
Fluid Pan, Gasket and Filter
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
NOTE: Install a new transmission fluid filter.
1. With the vehicle in PARK, position on a hoist. 2. Remove the components in the order indicated
in the illustration and table.
3. To install, reverse the removal procedure. 4. Partially fill the transmission.
Item 6: Transmission Fluid Pan Filter Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 5318
1. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly sealed on the filter.
Lubricate the seals and install the transmission fluid filter.
Item 3: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Item 2: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications
Fluid Pump: Specifications
Fluid pump housing screws .................................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Specifications
Output Shaft: Specifications
Rear output flange nut .........................................................................................................................
................................................. 355 Nm (262 ft. lbs.) Rear output shaft speed sensor bolt
......................................................................................................................................................... 5
Nm (44 inch lbs.) Front output shaft speed sensor bolt
........................................................................................................................................................ 5
Nm (44 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams
Overdrive Switch: Diagrams
Transmission Control Switch (TCS) C/O
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair
Parking Pawl: Service and Repair
Park System
Special Tools
Special Tool(s)
Removal
NOTE: If damage to the park gear is found, the transmission must be removed and disassembled
to install a new park gear.
NOTE: The park pawl, park pawl return spring and the park pawl shaft may fall out when removing
the extension housing.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect. If damage to the gasket is
found, a new gasket must be installed.
1. On 4x4 vehicles, remove the transfer case assembly. 2. On 4x2 vehicles, remove the driveshaft.
3. On 4x2 vehicles, remove the rear transmission support insulator. 4. On 4x2 vehicles, remove the
exhaust. 5. It is not necessary to remove the shift cable and bracket from the transmission.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5331
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5332
6. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Item 1: Transmission Range (TR) Sensor Electrical Connector Removal Note
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5333
Item 15: Manual Control Lever Inner Nut Removal Note
1. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever
pin.
Remove the manual control lever inner nut.
Item 18: Manual Control Valve Detent Inner Lever Removal Note
1. Disconnect the manual valve inner lever from the parking lever actuating rod.
2. Remove the manual valve inner lever.
Installation
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5334
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5335
1. Illustration 2 of 2. Install the components in the order indicated in the illustration and table. 2. On
4x4 vehicles, install the transfer case assembly. 3. On 4x2 vehicles, install the driveshaft. 4. On 4x2
vehicles, install the rear transmission support insulator. 5. On 4x2 vehicles, install the exhaust. 6.
Partially fill the transmission.
Item 2: Manual Control Valve Detent Inner Lever Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5336
1. Install and assemble the manual valve inner lever and parking pawl actuating rod as shown.
Item 3: Manual Control Lever Shaft Installation Note
1. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control
lever shaft.
Align the flats on 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.
Item 4: Manual Control Lever Inner Nut Installation Note
1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
Item 5: Manual Control Lever Shaft Retaining Pin Installation Note
1. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5337
NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft
spring pin bore in the transmission case.
Install the manual control lever shaft spring pin. ^
Tap the manual control lever shaft spring pin into the transmission case.
Item 6: Manual Control Lever Inner Nut Installation Note
1. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
Tighten the nut.
Item 7: Manual Valve Detent Spring Installation Note
1. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
Item 13: Extension Housing Installation Note
1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the 4x4 extension housing.
2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the 4x2 extension housing.
Item 15: Transmission Fluid Filter Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5338
1. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
Lubricate the seals and install the transmission fluid filter.
Item 18: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Item 19: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 21: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5339
Install the digital TR sensor and loosely install the screws.
Item 22: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Item 26: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5345
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5346
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5347
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5348
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5349
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5350
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5351
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5352
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5353
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5354
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5355
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5356
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5357
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5358
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5359
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5360
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5361
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5362
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5363
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5364
Pressure Regulating Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5365
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5366
Pressure Regulating Solenoid: Description and Operation
Pressure Control Solenoids (PCA, PCB, PCC)
The pressure control (PC) solenoids are a variable-force style (VFS) solenoid. The VFS-type
solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off
while verifying the output from the other solenoid. The second pressure tap is used to verify the
output from the PC C solenoid.
There are three PC solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
The powertrain control module (PCM) varies the current to the PC solenoid.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5367
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5368
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 5369
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair
Seals and Gaskets: Service and Repair
Extension Housing Seal-4x4
Special Tool(s)
1. Remove the transfer case assembly. 2. Remove the components in the order indicated in the
illustration and table.
3. To install, reverse the removal procedure 4. Carry out fluid level check.
Item 1: Output Shaft Seal Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Page 5373
1. Using the special tools, remove the extension housing seal.
Item 1: Output Shaft Seal Installation Note
1. NOTE: Make sure the extension housing seal is correctly installed onto the special tool and the
garter spring is in the correct position.
Using the special tool, install the extension housing seal.
Extension Housing Gasket-4x4
1. Remove the transfer case assembly. 2. Remove the components in the order indicated in the
illustration and table. 3. To install, reverse the removal procedure. 4. Carry out fluid level check.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Page 5374
Item 2: Extension Housing Removal Note
1. 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.
Item 2: Extension Housing Installation Note
1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the extension housing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams
Overdrive Switch: Diagrams
Transmission Control Switch (TCS) C/O
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Locations > Page 5382
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5386
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5387
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5388
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5389
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Speed sensor screws ..........................................................................................................................
....................................................... 14 Nm (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5395
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5396
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5399
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5400
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor >
Page 5403
1. Remove the OSS sensor.
1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the OSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor >
Page 5404
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor >
Page 5405
1. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the transmission.
^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the TSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor >
Page 5406
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor >
Page 5407
1. Remove the intermediate shaft speed sensor.
1 Remove the intermediate shaft speed sensor screw.
2 Remove the intermediate shaft speed sensor from the transmission.
^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the intermediate shaft speed sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 solenoid body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5413
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5414
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5415
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5416
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5417
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5418
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5419
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5420
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5421
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5422
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5423
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5424
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5425
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5426
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5427
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5428
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5429
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5430
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5431
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5432
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5433
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 solenoid body. - The PCM uses the TFT signal to help determine shift
scheduling, torque converter clutch operation and pressure control requirements.
It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature.
The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift
schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits
torque converter clutch (TCC) operation at low transmission fluid temperatures and use to
determine pressure control (PC) solenoid operations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair
Shift Interlock Solenoid: Service and Repair
Removal and Installation
NOTE: Some 2002-2005 Explorer 4 Dr/Mountaineer vehicles may require a greater effort to move
the gear selector lever from drive to park. This may be due to a time delay with the brake shift
interlock pin retraction.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 fasteners supporting the instrument panel knee bolster from below the steering
column and remove the cover.
3. Remove the 3 fasteners supporting the steering column lower shroud and remove the cover.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair > Page 5438
4. Remove the 3 wiring bundle carrier fasteners from the bottom of the steering column to allow
movement while removing the brake shift interlock
switch. It may be necessary to release the connectors from the multifunction switch.
5. Remove the brake shift interlock bolts.
6. Pull the brake shift interlock tab on the bottom of the column downward to help free the brake
shift interlock from the column housing.
7. Break the 2 side tabs off the brake shift interlock by the white wiring connector.
8. Push the locking tab on the white connector towards the wiring to release the connector from the
brake shift interlock. Be careful not to damage
the connector or wiring. If the connector does not free easily, a very small flat screwdriver may be
used to help lift the locking tab.
9. Connect the wiring to the new brake shift interlock. Make sure all clips are fully engaged to
prevent the connector from pulling free.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair > Page 5439
10. Position the brake shift interlock onto the steering column and reinstall fasteners.
11. Check brake shift interlock function. With the key in the accessory or run position, press the
brake pedal. The brake shift interlock pin should
retract on brake application and spring up 1 second after releasing the brake pedal. Repeat several
times.
12. Reinstall the fasteners to connect the wiring bundle carrier to the steering column. Make sure
all connections to the multifunction switch unit are
secured correctly.
13. Assemble the steering column in reverse order. Make sure the rubber gap hider around the
shift lever is correctly seated on the shroud.
14. Cycle the shift lever from park to drive and drive back to park several times to verify improved
shift effort.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations
Shift Solenoid: Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5445
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5446
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5447
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5448
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5449
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5450
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5451
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5452
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5453
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5454
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5455
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5456
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5457
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5458
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5459
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5460
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5461
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5462
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5463
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5464
Shift Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5465
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5466
Shift Solenoid: Description and Operation
Shift Solenoids (SSA, SSB, SSC, SSD)
Four On/Off shift solenoids allow the powertrain control module (PCM) to control shift scheduling.
The solenoids are three-way, normally open style. The shift solenoids SSA, SSB, SSC, and SSD
provide gear selection of first through fifth and reverse gears by directing PC pressures to the
appropriate elements. Coast braking and manual gears are also controlled by the shift solenoids.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5467
Shift Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5468
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5469
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications
Torque Converter: Specifications
Torque converter adapter plate-to-converter nuts
..................................................................................................................................... 38 Nm (28 ft.
lbs.) Torque converter adapter plate-to-flexplate nuts
...................................................................................................................................... 38 Nm (28 ft.
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Locations
Torque Converter Clutch Solenoid: Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5478
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5479
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5480
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5481
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5482
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5483
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5484
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5485
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5486
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5487
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5488
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5489
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5490
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5491
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5492
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5493
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5494
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5495
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5496
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5497
Torque Converter Clutch Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5498
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5499
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is a pulse width modulating type solenoid which is used
to control the apply and release of the TCC.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5500
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5501
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5502
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications
Transmission Cooler: Specifications
Transmission cooler fitting-to-case
...........................................................................................................................................................
47 Nm (35 ft. lbs.) Transmission cooler tube nut-to-case fitting
............................................................................................................................................. 30 Nm
(22 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Transmission Cooler: Initial Inspection and Diagnostic Overview
Inspection and Verification
Check for fluid leakage. If fluid leakage is found at any of the transmission fluid cooling
components, a new component must be installed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5508
Transmission Cooler: Symptom Related Diagnostic Procedures
Symptom Chart
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Page 5509
Transmission Cooler: Tools and Equipment
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Locations > Page 5513
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair
Transmission Mount: Service and Repair
Transmission Support Insulator- 4x4
1. With the vehicle in PARK, position on a hoist. 2. Support the transmission with a transmission
jack.
3. Remove the components in the order indicated the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Page 5517
4. To install, reverse the removal procedure.
Item 10: Exhaust Hanger Removal Note
1. Position the hanger out of the way.
Item 10: Exhaust Hanger Installation Note
1. Install the exhaust hanger prior to installing the screw for the rear support insulator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5521
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5522
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5523
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5524
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Speed sensor screws ..........................................................................................................................
....................................................... 14 Nm (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5530
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5531
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5534
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5535
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5538
1. Remove the OSS sensor.
1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the OSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5539
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5540
1. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the transmission.
^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the TSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5541
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5542
1. Remove the intermediate shaft speed sensor.
1 Remove the intermediate shaft speed sensor screw.
2 Remove the intermediate shaft speed sensor from the transmission.
^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the intermediate shaft speed sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 solenoid body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5548
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5549
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5554
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5555
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5556
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5557
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5558
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5559
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5560
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5561
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5562
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5563
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5564
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5565
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5566
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5567
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Page 5568
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 solenoid body. - The PCM uses the TFT signal to help determine shift
scheduling, torque converter clutch operation and pressure control requirements.
It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature.
The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift
schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits
torque converter clutch (TCC) operation at low transmission fluid temperatures and use to
determine pressure control (PC) solenoid operations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Main Control Valve Body
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.
NOTE: The valve body separator plate has a bonded gasket. Do not reuse, discard the bonded
gasket.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5574
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5575
1. Remove the components in the order indicated in the illustration and table. To remove, clean
and inspect the valves, carry out the steps listed.
2. After cleaning the main control valve body, carry out the following.
- Inspect all valve and plug bores for scoring or burrs.
- Check all fluid passages for obstructions.
- Inspect all valves and plugs for burrs.
- Inspect all mating surfaces for burrs or distortion.
- Inspect all springs for distortion.
- Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight into their respective bores.
- Roll the manual valve on a flat surface to check for a bent condition.
3. Assemble in the reverse order of disassembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5576
Items 1 and 2: Main Control Valve Body Separator Plate Assembly Note
1. NOTE: Use a new valve body separator plate for main control valve body installation.
Using the special tools, install the main control valve body separator plate.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5577
Valve Body: Service and Repair Removal and Installation
Main Control Valve Body
Main Control Valve Body
Special Tool(s)
CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5578
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5579
4. To install, reverse the removal procedure. 5. Partially fill the transmission.
Item 22: Main Control Valve Body Installation Note
1. Install the special tools into the transmission case.
Item 19, 20 and 21: Main Control Valve Body Screws Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5580
1. Using the special tools, install the main control valve body and loosely install the screws.
1 Install the short screw.
2 Install the screw with the larger head.
3 Install the remaining screws.
2. Remove the special tools, and loosely install the screw.
3. Tighten the screws in the sequence shown.
Item 15: Reverse Servo Screws Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5581
1. Install the reverse servo. Tighten the screws in the sequence shown.
Item 14: Solenoid Body O-rings Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Items 11,12 and 13: Solenoid Body and Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If it is damaged, transmission leak
may occur.
Install the solenoid body. Tighten the screws in sequence shown.
Item 10: Transmission Fluid Pan Filter Installation Note
1. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be
damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5582
Lubricate the seals and install the transmission fluid filter.
Item 7: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Item 6: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 5: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above
specification.
NOTE: Always install new O-ring seals on vehicle harness connector.
NOTE: Clean the area around connector to prevent contamination of the solenoid body connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Solenoid Body Assembly
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5583
strategy. The customer needs to be notified that they may experience slightly different upshifts
(either soft or firm) and this is a temporary condition and will eventually return to normal operating
condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5584
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 5585
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Hydraulic Hose, Clutch > Component Information >
Tools and Equipment
Hydraulic Hose: Tools and Equipment
Clutch Line Fork
AST tool# 8008
Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This
tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford
Aerostar, Bronco II, Explorer, F150 and Ranger.
- For R and R of Hydraulic Clutch Lines
- Applicable to Ford Models with Manual Transmissions
- Steel Construction
- Black-Oxide Finish
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 06-4-4 > Mar > 06 > Drivetrain Limited Slip Differential Chatter
Differential Clutch: Customer Interest Drivetrain - Limited Slip Differential Chatter
TSB 06-4-4
03/06/06
LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING
LOW SPEED TURNING MANEUVERS
FORD: 2002-2004 Mustang, Explorer 2003-2004 Expedition 2004 F-150
LINCOLN: 2003 Navigator
MERCURY: 2002-2004 Mountaineer
This article supersedes TSB 06-02-16 to update the Service Procedure.
ISSUE Some 2003-2004 Expedition, 2003 Navigator, 2004 F-150 vehicles equipped with a 9.75" or
8.8" limited slip rear axle, and 2002-2004 Explorer 4dr, Mountaineer, and Mustang vehicles
equipped with 8.8" limited slip rear axle may exhibit a chatter shudder, a binding sensation, or a
vibration during low speed turns. On 4X4 vehicles, the sensation may appear to be originating from
the front axle or the steering gear.
ACTION First verify the condition. On 4X4 trucks ensure that the vehicle is in 2WD, to isolate the
rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If
the condition is verified to be in the rear axle, replace the limited slip clutch pack.
SERVICE PROCEDURE
CAUTION
INSTRUCT THE CUSTOMER NOT TO TOW WITH THE VEHICLE FOR 500 MILES (805 KM)
AFTER THIS REPAIR, TO ALLOW THE AXLE TO BREAK-IN PROPERLY.
Order and install the appropriate clutch pack, follow the instructions detailed in the Workshop
Manual.
^ 6L1Z-4947-A (9.75" limited slip)
^ F5AZ-4947-BA (8.8" limited slip)
NOTE
INSTALLING A CLUTCH PACK INTO AN INDEPENDENT REAR SUSPENSION (IRS) AXLE IS
DIFFERENT FROM INSTALLING A CLUTCH PACK INTO A SOLID-BEAM AXLE. BE SURE TO
FOLLOW THE APPROPRIATE WORKSHOP MANUAL PROCEDURE.
INSTALLATION TIPS
^ Be sure to install NEW circlips and halfshaft/wheel end nuts on IRS rear axle (not included in the
service kit)
^ Soak the new clutch packs in Additive Friction Modifier (XL-3) for fifteen (15) minutes prior to
installation
^ For IRS axles, the half shaft seals need to be replaced. Expedition and Explorer/Mountaineer
applications should use seal kit part number SL1Z-4A109-A. Removal of the half shaft excluder
seal 1L2Z-1N013 may be required, if equipped, to facilitate re-assembly
^ Refill axles with 4 oz. Additive Friction Modifier (XL-3) and the necessary amount of Rear Axle
Lubricant (XY-75W140-QL), regardless of the axle lubricant system originally used in the axle. Fill
to capacity recommended in the Workshop Manual
NOTE
AXLE FLUID REQUIREMENTS HAVE BEEN CHANGED. ALL VEHICLES BEING REPAIRED BY
THIS TSB MUST HAVE REAR AXLE LUBE XY-75W140-QL INSTALLED, IN PLACE OF
XY75W90-QFEHP. AS PART OF THIS REPAIR, CHECK AND REPLACE IF NECESSARY THE
CURRENT XY-75W90-Q"FEHP" METAL TAG, WITH A NEW 75W140 TAG (F3TZ-4121-AA).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 06-4-4 > Mar > 06 > Drivetrain Limited Slip Differential Chatter > Page 5599
ADDITIONALLY, REMOVE THE MULTI-COLORED LABEL WHICH IS LOCATED ON THE RIGHT
SIDE, AXLE TUBE, OR BLOCK OUT ANY/ALL "FEHP" OR "75W90" REFERENCES ON THE
LABEL.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060404A 2003-2004 Expedition 4.5 Hrs.
Without Air Suspension: Replace Clutch Pack (Includes Time For Road Test To Verify Concern,
Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A 4010D, 4010D1, 4010D4,
4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8,
4205A12, 4205A13 4205A14 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404B 2003-2004 Expedition, 4.7 Hrs.
2003 Navigator With Air Suspension: Replace Clutch Pack (Includes Time For Road Test To Verify
Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not
Use With 4010A, 4010D,
4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B, 4205A, 4205A4, 4205A5,
4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404C 2002-2004 Explorer, 4.9 Hrs.
Mountaineer: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear
Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 06-4-4 > Mar > 06 > Drivetrain Limited Slip Differential Chatter > Page 5600
4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5,
4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404D 2004 F-150: Replace 3.2 Hrs.
Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And
Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12,
4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13,
4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404E 2002-2004 Mustang: 3.1 Hrs.
Replace Clutch Pack (Includes Time For Road Test To Verity Concern, Replace Rear Clutch Pack,
And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6,
4010D12, 4010D13, 4033A, 4200B, 4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12,
4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404F 2002-2004 Mustang Cobra: 5.9 Hrs.
Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack,
And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6,
4010D12, 4010D13, 4033A, 4200B, 4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12,
4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4947 D4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 06-4-4 > Mar > 06 > Drivetrain Limited Slip Differential Chatter > Page 5601
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 06-4-4 > Mar > 06 >
Drivetrain - Limited Slip Differential Chatter
Differential Clutch: All Technical Service Bulletins Drivetrain - Limited Slip Differential Chatter
TSB 06-4-4
03/06/06
LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING
LOW SPEED TURNING MANEUVERS
FORD: 2002-2004 Mustang, Explorer 2003-2004 Expedition 2004 F-150
LINCOLN: 2003 Navigator
MERCURY: 2002-2004 Mountaineer
This article supersedes TSB 06-02-16 to update the Service Procedure.
ISSUE Some 2003-2004 Expedition, 2003 Navigator, 2004 F-150 vehicles equipped with a 9.75" or
8.8" limited slip rear axle, and 2002-2004 Explorer 4dr, Mountaineer, and Mustang vehicles
equipped with 8.8" limited slip rear axle may exhibit a chatter shudder, a binding sensation, or a
vibration during low speed turns. On 4X4 vehicles, the sensation may appear to be originating from
the front axle or the steering gear.
ACTION First verify the condition. On 4X4 trucks ensure that the vehicle is in 2WD, to isolate the
rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If
the condition is verified to be in the rear axle, replace the limited slip clutch pack.
SERVICE PROCEDURE
CAUTION
INSTRUCT THE CUSTOMER NOT TO TOW WITH THE VEHICLE FOR 500 MILES (805 KM)
AFTER THIS REPAIR, TO ALLOW THE AXLE TO BREAK-IN PROPERLY.
Order and install the appropriate clutch pack, follow the instructions detailed in the Workshop
Manual.
^ 6L1Z-4947-A (9.75" limited slip)
^ F5AZ-4947-BA (8.8" limited slip)
NOTE
INSTALLING A CLUTCH PACK INTO AN INDEPENDENT REAR SUSPENSION (IRS) AXLE IS
DIFFERENT FROM INSTALLING A CLUTCH PACK INTO A SOLID-BEAM AXLE. BE SURE TO
FOLLOW THE APPROPRIATE WORKSHOP MANUAL PROCEDURE.
INSTALLATION TIPS
^ Be sure to install NEW circlips and halfshaft/wheel end nuts on IRS rear axle (not included in the
service kit)
^ Soak the new clutch packs in Additive Friction Modifier (XL-3) for fifteen (15) minutes prior to
installation
^ For IRS axles, the half shaft seals need to be replaced. Expedition and Explorer/Mountaineer
applications should use seal kit part number SL1Z-4A109-A. Removal of the half shaft excluder
seal 1L2Z-1N013 may be required, if equipped, to facilitate re-assembly
^ Refill axles with 4 oz. Additive Friction Modifier (XL-3) and the necessary amount of Rear Axle
Lubricant (XY-75W140-QL), regardless of the axle lubricant system originally used in the axle. Fill
to capacity recommended in the Workshop Manual
NOTE
AXLE FLUID REQUIREMENTS HAVE BEEN CHANGED. ALL VEHICLES BEING REPAIRED BY
THIS TSB MUST HAVE REAR AXLE LUBE XY-75W140-QL INSTALLED, IN PLACE OF
XY75W90-QFEHP. AS PART OF THIS REPAIR, CHECK AND REPLACE IF NECESSARY THE
CURRENT XY-75W90-Q"FEHP" METAL TAG, WITH A NEW 75W140 TAG (F3TZ-4121-AA).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 06-4-4 > Mar > 06 >
Drivetrain - Limited Slip Differential Chatter > Page 5607
ADDITIONALLY, REMOVE THE MULTI-COLORED LABEL WHICH IS LOCATED ON THE RIGHT
SIDE, AXLE TUBE, OR BLOCK OUT ANY/ALL "FEHP" OR "75W90" REFERENCES ON THE
LABEL.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060404A 2003-2004 Expedition 4.5 Hrs.
Without Air Suspension: Replace Clutch Pack (Includes Time For Road Test To Verify Concern,
Replace Rear Clutch Pack, And Re-Road Test) (Do Not Use With 4010A 4010D, 4010D1, 4010D4,
4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8,
4205A12, 4205A13 4205A14 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404B 2003-2004 Expedition, 4.7 Hrs.
2003 Navigator With Air Suspension: Replace Clutch Pack (Includes Time For Road Test To Verify
Concern, Replace Rear Clutch Pack, And Re-Road Test) (Do Not
Use With 4010A, 4010D,
4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B, 4205A, 4205A4, 4205A5,
4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404C 2002-2004 Explorer, 4.9 Hrs.
Mountaineer: Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear
Clutch Pack, And Re-Road Test) (Do Not Use With 4010A, 4010D,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 06-4-4 > Mar > 06 >
Drivetrain - Limited Slip Differential Chatter > Page 5608
4010D1, 4010D4, 4010D5, 4010D6, 4010D12, 4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5,
4205A6, 4205A8, 4205A12, 4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404D 2004 F-150: Replace 3.2 Hrs.
Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack, And
Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6, 4010D12,
4010D13, 4033A, 4200B,4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12, 4205A13,
4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404E 2002-2004 Mustang: 3.1 Hrs.
Replace Clutch Pack (Includes Time For Road Test To Verity Concern, Replace Rear Clutch Pack,
And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6,
4010D12, 4010D13, 4033A, 4200B, 4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12,
4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
060404F 2002-2004 Mustang Cobra: 5.9 Hrs.
Replace Clutch Pack (Includes Time For Road Test To Verify Concern, Replace Rear Clutch Pack,
And Re-Road Test) (Do Not Use With 4010A, 4010D, 4010D1, 4010D4, 4010D5, 4010D6,
4010D12, 4010D13, 4033A, 4200B, 4205A, 4205A4, 4205A5, 4205A6, 4205A8, 4205A12,
4205A13, 4205A14, 4234A, 4139A, 4139A2, 052303, 051505, 4602A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4947 D4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 06-4-4 > Mar > 06 >
Drivetrain - Limited Slip Differential Chatter > Page 5609
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Technical Service Bulletins > Customer Interest for Differential Axle Housing: > 04-17-15 > Sep > 04 >
Drivetrain - Front Axle Tube Seal Leak
Differential Axle Housing: Customer Interest Drivetrain - Front Axle Tube Seal Leak
TSB 04-17-15
09/06/04
FRONT AXLE TUBE SEAL LEAK
FORD: 2003-2004 Explorer
LINCOLN: 2003-2004 Aviator
MERCURY: 2003-2004 Mountaineer
ISSUE
Some 2003-2004 Explorer/Mountaineer/Aviator 4X4 vehicles built 07/01/03 through 09/30/03 may
exhibit a front axle oil seal leak condition.
ACTION
Inspect the passenger side front axle tube seal bore surface for signs of the seal spinning in the
bore. If seal is spinning in the bore, axle replacement is required. If the seal bore appears free from
damage, replace the seal only. Inspect axle shaft sealing surface for damage and service as
necessary. Refer to Workshop Manual Section 205-00 for procedures.
PARTS BLOCK
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041715A Inspect And 2.3 Hr.
Replace Axle Assembly
041715B Inspect And 1.1 Hr.
Replace Axle Seal Only
DEALER CODING
CONDITION
BASIC PART NO. CODE
3254 D8
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Axle Housing: > 04-17-15 > Sep >
04 > Drivetrain - Front Axle Tube Seal Leak
Differential Axle Housing: All Technical Service Bulletins Drivetrain - Front Axle Tube Seal Leak
TSB 04-17-15
09/06/04
FRONT AXLE TUBE SEAL LEAK
FORD: 2003-2004 Explorer
LINCOLN: 2003-2004 Aviator
MERCURY: 2003-2004 Mountaineer
ISSUE
Some 2003-2004 Explorer/Mountaineer/Aviator 4X4 vehicles built 07/01/03 through 09/30/03 may
exhibit a front axle oil seal leak condition.
ACTION
Inspect the passenger side front axle tube seal bore surface for signs of the seal spinning in the
bore. If seal is spinning in the bore, axle replacement is required. If the seal bore appears free from
damage, replace the seal only. Inspect axle shaft sealing surface for damage and service as
necessary. Refer to Workshop Manual Section 205-00 for procedures.
PARTS BLOCK
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041715A Inspect And 2.3 Hr.
Replace Axle Assembly
041715B Inspect And 1.1 Hr.
Replace Axle Seal Only
DEALER CODING
CONDITION
BASIC PART NO. CODE
3254 D8
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Technical Service Bulletins > Page 5623
Differential Axle Housing: Specifications
Maximum spread of differential housing
........................................................................................................................................... 0.381 mm
(0.015 inch) Rear differential housing cover bolt
......................................................................................................................................................... 32
Nm (24 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component
Information > Specifications
Fill Plug: Specifications
Filler plug .............................................................................................................................................
.................................................... 34 Nm (25 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Rear Axle..............................................................................................................................................
.......................................................1.65 L (3.5 pints)*
Additive Friction Modifier......................................................................................................................
................................................0.12 L (0.25 pints)**
Front Axle..............................................................................................................1.54 L (2.7 pints)
(9.56 mm (0.38 in) below the bottom of the filler hole)
* Fill to the bottom of the filler hole, then add 0.425 L (0.9 pint) through the ABS sensor hole.
** Install friction modifier before installing axle lubricant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 5631
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
REAR AXLE* SAE 75W-140 High Performance Rear Axle Lubricant Ford P/N .................................
..............................................................................................................................................................
...... XY-75W140-QL Ford Specification ..............................................................................................
........................................................................................ WSL-M2C192-A
FRONT AXLE SAE 80W-90 Premium Rear Axle Lubricant Ford P/N .................................................
......................................................................................................................................................
XY-80W90-QL Ford Specification .......................................................................................................
............................................................................... WSP-M2C197-A
Additive Friction Modifier XL-3 Ford P/N .............................................................................................
........................................................................................................................... XL-3 Ford
Specification ........................................................................................................................................
............................................... EST-M2C118-A
* If fluid is required, replace the original FEHP lubricant with 75W-140. Remove the old tag and
install a new tag.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Specifications
Pinion Bearing: Specifications
Rear
Pinion bearing preload (used pinion bearings)
....................................................................................................................... 0.9-1.5 Nm (8-14 inch
lbs.) Pinion bearing preload (new pinion bearings)
...................................................................................................................... 1.8-3.3 Nm (16-29 inch
lbs.) Available drive pinion bearing adjustment shim in steps of 0.25 mm (0.010 inch)
............................... 0.254 mm (0.010 inch) - 0.965 mm (0.038 inch)
Front
Pinion bearing preload (used pinion bearings) .................................................................. 0.56 Nm
(5 inch lbs.) more than recorded disassembly torque Pinion bearing preload (new pinion bearings)
...................................................................................................................... 1.7-3.4 Nm (15-30 inch
lbs.) Available drive pinion bearing adjustment shim in steps of 0.05 mm (0.002 inch)
...................................................... 1.35-1.85 mm (0.053-0.073 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Specifications
Pinion Flange: Specifications
Pinion flange maximum radial runout in assembly
.............................................................................................................................. 0.25 mm (0.010
inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle
Pinion Flange: Service and Repair Drive Pinion Flange and Drive Pinion Seal-Front Axle
Drive Pinion Flange and Drive Pinion Seal-Front Axle
Special Tool(s)
Material
CAUTION: This operation disturbs the differential pinion bearing preload. Carefully reset the
preload during assembly.
1. With the vehicle in NEUTRAL, position on a hoist.
2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during
the drive pinion preload recording and adjustment.
Remove the front tires and wheels.
3. Remove the front disc brake calipers and position them aside.
4. CAUTION: Do not allow the driveshaft to hang unsupported.
Disconnect the front driveshaft from the pinion flange and position it aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5640
5. Remove the components in the order indicated in the illustration and table.
6. To install, reverse the removal procedure. 7. Check the lubricant level in the front axle assembly
and, if necessary, fill the axle to specification.
Item 1: Pinion Nut and Washer Removal Note
1. Measure and record the pinion bearing tongue preload.
^ Using a Nm (inch-pound) torque wrench, rotate the pinion. Measure the torque required to
maintain pinion rotation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5641
2. Index-mark the pinion flange and the pinion stem.
3. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
Item 2: Pinion Flange Removal Note
1. Using the special tool, remove the pinion flange. 2. Inspect the pinion flange for burrs and
damage. Inspect the end of the pinion flange that contacts the bearing cone, nut counterbore and
seal
surface for nicks. Discard the pinion flange if damaged.
Item 3: Pinion Oil Seal Removal Note
1. Using the special tool, remove the pinion seal. 2. Verify the splines on the pinion stem are free of
burrs. If burrs are evident, remove them with a fine crocus cloth. 3. Clean the pinion seal bore.
Item 3: Pinion Oil Seal Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5642
1. NOTE: Lubricate the pinion seal lips with axle lubricant.
Using the special tool, install the pinion seal.
Item 2: Pinion Flange Installation Note
1. CAUTION: Never use a hammer or install the flange with power tools.
7NOTE: Lubricate the pinion flange splines.
Align the index marks and using the special tool, install the pinion flange.
Item 1: Pinion Nut and Washer Installation Note
1. Install the new washer and pinion nut. Only hand-tighten the nut at this time.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5643
2. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if
preload reduction is necessary.
Using the special tool to hold the pinion flange, tighten the nut to set the preload. ^
Tighten the nut, rotating the pinion occasionally to make sure 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5644
Pinion Flange: Service and Repair Drive Pinion Flange and Drive Pinion Seal-Rear Axle
Drive Pinion Flange and Drive Pinion Seal-Rear Axle
Special Tool(s)
Material
1. With the vehicle in NEUTRAL, position on a 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 allow the calipers to hang from the brake hoses.
Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the
caliper and support bracket out of the way.
4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange to maintain initial
balance during installation.
Disconnect and position the driveshaft out of the way.
5. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5645
6. To install, reverse the removal procedure. 7. Fill the axle with the specified quantity of the
specified lubricant.
Item 1: Pinion Nut Removal Note
1. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque necessary to
maintain rotation of the drive pinion gear through
several revolutions.
2. CAUTION: After removing the nut, discard it. Always use a new nut for installation.
Use the special tool to hold the rear axle pinion flange while removing the nut.
Item 2: Rear Axle Pinion Flange Removal Note
1. Index-mark the rear axle pinion flange and drive pinion gear to maintain initial balance during
installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5646
2. Using the special tool, remove the rear axle pinion flange.
Item 3: Rear Pinion Oil Seal Removal Note
1. Use a screwdriver to force up the metal flange of the rear axle drive pinion seal. Install gripping
pliers and strike with a hammer to remove the rear
axle drive pinion seal.
Item 3: Rear Pinion Oil Seal Installation Note
1. Lubricate the lips of the new seal with grease.
2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
seal and install a new one.
Using the special tool, install the rear axle drive pinion seal.
Item 2: Rear Axle Pinion Flange Installation Note
1. 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.
2. Lubricate the rear axle pinion flange splines.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5647
3. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange.
4. Using the special tools, install the rear axle pinion flange.
Item 1: Pinion Nut Installation Note
1. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to
reduce preload, install a new differential drive
pinion collapsible spacer and nut.
Tighten the nut to set the preload. ^
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing torque preload readings by rotating the drive pinion gear 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 the torque specification for used pinion bearings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Specifications
Ring Gear: Specifications
Rear Axle
Backlash between ring gear and pinion teeth
............................................................................................................ 0.254-0.305 mm (0.010-0.012
inch) Ring gear maximum variation between teeth
................................................................................................................................. 0.102 mm (0.004
inch)
Front Axle
Ring gear backlash
........................................................................................................................................................
0.13-0.20 mm (0.005-0.008 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle
Seals and Gaskets: Service and Repair Drive Pinion Flange and Drive Pinion Seal-Front Axle
Drive Pinion Flange and Drive Pinion Seal-Front Axle
Special Tool(s)
Material
CAUTION: This operation disturbs the differential pinion bearing preload. Carefully reset the
preload during assembly.
1. With the vehicle in NEUTRAL, position on a hoist.
2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during
the drive pinion preload recording and adjustment.
Remove the front tires and wheels.
3. Remove the front disc brake calipers and position them aside.
4. CAUTION: Do not allow the driveshaft to hang unsupported.
Disconnect the front driveshaft from the pinion flange and position it aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5655
5. Remove the components in the order indicated in the illustration and table.
6. To install, reverse the removal procedure. 7. Check the lubricant level in the front axle assembly
and, if necessary, fill the axle to specification.
Item 1: Pinion Nut and Washer Removal Note
1. Measure and record the pinion bearing tongue preload.
^ Using a Nm (inch-pound) torque wrench, rotate the pinion. Measure the torque required to
maintain pinion rotation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5656
2. Index-mark the pinion flange and the pinion stem.
3. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
Item 2: Pinion Flange Removal Note
1. Using the special tool, remove the pinion flange. 2. Inspect the pinion flange for burrs and
damage. Inspect the end of the pinion flange that contacts the bearing cone, nut counterbore and
seal
surface for nicks. Discard the pinion flange if damaged.
Item 3: Pinion Oil Seal Removal Note
1. Using the special tool, remove the pinion seal. 2. Verify the splines on the pinion stem are free of
burrs. If burrs are evident, remove them with a fine crocus cloth. 3. Clean the pinion seal bore.
Item 3: Pinion Oil Seal Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5657
1. NOTE: Lubricate the pinion seal lips with axle lubricant.
Using the special tool, install the pinion seal.
Item 2: Pinion Flange Installation Note
1. CAUTION: Never use a hammer or install the flange with power tools.
7NOTE: Lubricate the pinion flange splines.
Align the index marks and using the special tool, install the pinion flange.
Item 1: Pinion Nut and Washer Installation Note
1. Install the new washer and pinion nut. Only hand-tighten the nut at this time.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5658
2. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if
preload reduction is necessary.
Using the special tool to hold the pinion flange, tighten the nut to set the preload. ^
Tighten the nut, rotating the pinion occasionally to make sure 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5659
Seals and Gaskets: Service and Repair Drive Pinion Flange and Drive Pinion Seal-Rear Axle
Drive Pinion Flange and Drive Pinion Seal-Rear Axle
Special Tool(s)
Material
1. With the vehicle in NEUTRAL, position on a 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 allow the calipers to hang from the brake hoses.
Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the
caliper and support bracket out of the way.
4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange to maintain initial
balance during installation.
Disconnect and position the driveshaft out of the way.
5. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5660
6. To install, reverse the removal procedure. 7. Fill the axle with the specified quantity of the
specified lubricant.
Item 1: Pinion Nut Removal Note
1. Install a Nm (inch-pound) torque wrench on the pinion nut and record the torque necessary to
maintain rotation of the drive pinion gear through
several revolutions.
2. CAUTION: After removing the nut, discard it. Always use a new nut for installation.
Use the special tool to hold the rear axle pinion flange while removing the nut.
Item 2: Rear Axle Pinion Flange Removal Note
1. Index-mark the rear axle pinion flange and drive pinion gear to maintain initial balance during
installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5661
2. Using the special tool, remove the rear axle pinion flange.
Item 3: Rear Pinion Oil Seal Removal Note
1. Use a screwdriver to force up the metal flange of the rear axle drive pinion seal. Install gripping
pliers and strike with a hammer to remove the rear
axle drive pinion seal.
Item 3: Rear Pinion Oil Seal Installation Note
1. Lubricate the lips of the new seal with grease.
2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
seal and install a new one.
Using the special tool, install the rear axle drive pinion seal.
Item 2: Rear Axle Pinion Flange Installation Note
1. 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.
2. Lubricate the rear axle pinion flange splines.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal-Front Axle > Page 5662
3. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Position the rear axle pinion flange.
4. Using the special tools, install the rear axle pinion flange.
Item 1: Pinion Nut Installation Note
1. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to
reduce preload, install a new differential drive
pinion collapsible spacer and nut.
Tighten the nut to set the preload. ^
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing torque preload readings by rotating the drive pinion gear 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 the torque specification for used pinion bearings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals
Axle Shaft Assembly: Service and Repair Rear Axle Halfshafts, Bearings and Seals
Rear Axle Halfshafts, Bearings and Seals
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5668
Special Tool(s)
Material
NOTE: This procedure applies to both rear halfshaft assemblies.
1. CAUTION: Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly
are removed from the vehicle. Wheel bearing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5669
damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
With the vehicle in NEUTRAL, position on a hoist.
2. Remove the rear wheel and tire assembly. 3. Remove the components in the order indicated in
the illustration and table.
4. To install, reverse the removal procedure. 5. Fill the axle with the specified quantity of the
specified lubricant.
Item 1: Rear Disc Brake Caliper Removal Note
1. CAUTION: Do not allow the caliper to hang from the brake hose. Provide a suitable support.
Position the rear disc brake caliper aside.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5670
Item 2: Rear Axle Wheel Hub Retainer and Washer Removal Note
1. CAUTION: Do not use a hammer to separate the rear axle halfshaft assembly from the hub.
Damage to the threads and internal CV joint
components can result.
CAUTION: Once the rear axle halfshaft assembly separates from the hub, the knuckle will continue
to pivot until the brake backing plate presses against the suspension lower arm. To prevent
damage to the brake backing plate, immediately after separating the outboard CV joint from the
hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from
pressing against the suspension lower arm.
Separate the rear axle halfshaft assembly from the hub. 1
Using the special tool, press the outboard CV joint until it is loose in the hub.
2 Remove the special tool.
3 Separate the outboard CV joint from the hub.
Item 6: Rear Halfshaft Assembly Removal Note
1. CAUTION: Support the rear suspension upper arm to prevent boot damage when removing the
halfshaft assembly from the vehicle.
Using a wood stick approximately 450 mm (18 inch) long and 25 mm (1 inch) wide, support the rear
suspension upper arm.
2. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard
CV joint housing.
CAUTION: Do not allow the splines on the inboard CV joint housing to touch the axle shaft oil seal.
NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.
Using the special tool, disengage the inboard CV joint housing from the differential side gear.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5671
3. CAUTION: To prevent damage to the axle shaft oil seal, install the special tool before removing
the inboard CV joint housing from the axle.
Install the special tool.
4. For the inboard CV joint, carry out the following:
1 Remove and discard the boot clamps.
2 Remove the inboard CV joint housing.
5. For the inboard CV joint, carry out the following:
1 Remove and discard the retainer circlip.
2 Slide the boot away from the CV joint.
6. Using a suitable Claw puller, remove the CV joint.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5672
7. Remove and discard the tri-lobe insert and the boot.
8. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or
installed from the inboard CV joint side of the
shaft.
For the outboard CV joint, carry out the following: 1
Remove and discard the boot clamps.
2 Remove and discard the boot.
9. If necessary, press the brake anti-lock sensor indicator from the outer CV joint.
Item 7: Rear Stub Shaft Housing Bearing and Seal Removal Note
1. NOTE: If only a new rear stub shaft housing bearing seal is to be installed, engage the special
tool tangs on the seal.
Remove the stub shaft housing bearing and stub shaft housing bearing seal. 1
Install the special tool with the tangs firmly engaged on the stub shaft housing bearing.
2 Remove the stub shaft housing bearing and stub shaft housing bearing seal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5673
Item 7: Rear Stub Shaft Housing Bearing and Seal Installation Note
1. Lubricate the stub shaft housing bearing with axle lubricant. Place the stub shaft housing bearing
on the special tool.
2. Install the stub shaft housing axle housing bore.
3. Lubricate the lips of the stub shaft housing bearing seal with rear axle lubricant. Place the seal
on the special tool.
4. CAUTION: Installation of the stub shaft housing bearing and seal without the correct tool can
result in an early bearing or seal failure. If the
bearing or seal become cocked during installation, remove it and install a new one.
Carefully align the stub shaft housing bearing seal with the housing bore and install the seal.
Item 6: Rear Halfshaft Assembly Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5674
1. For the outboard CV joint, carry out the following:
1 Slide the boot on the interconnecting shaft.
2 Pack the outboard CV joint with 225 grams (7.93 oz.) of grease.
3 Spread any remaining grease evenly inside the boot.
4 Install the boot by seating it in the groove in the CV joint housing.
2. Using the special tool, install the boot clamps. 3. If necessary, install a new brake anti-lock
sensor indicator on the outer CV joint.
4. CAUTION: To prevent damage to the axle shaft oil seal, install the Differential Seal Protector
before positioning the inboard CV joint housing in
the axle.
CAUTION: Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub
retainer.
Install a new retainer circlip.
5. For the inboard CV joint, carry out the following:
1 Position the clamp on the interconnecting shaft.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5675
2 Position the boot on the interconnecting shaft.
3 Install the tri-lobe insert.
6. Using the special tool, install the CV joint.
7. Install the retainer circlip.
8. For the inboard CV joint, carry out the following:
1 Pack the inboard CV joint housing with 250 grams (8.82 oz.) of grease.
2 Spread any remaining grease evenly inside the boot and CV joint.
3 Install the inboard CV joint housing, seating the boot in the groove in the housing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5676
9. Set the halfshaft assembled length to specifications.
1 Measure the entire assembly length.
2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length.
3 Hold the inner joint to prevent the assembled length from changing, and insert a small flat-blade
screwdriver between the boot and the joint to equalize the pressure.
10. Using the special tool, install both boot clamps.
Item 2: Rear Axle Wheel Hub Retainer and Washer Installation Note
1. CAUTION: Never use power tools to tighten the rear axle wheel hub retainer.
Install a new rear axle wheel hub retainer and washer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5677
Axle Shaft Assembly: Service and Repair Front Axle Halfshafts, Bearings and Seals
Front Axle Halfshafts, Bearings and Seals
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5678
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5679
Material
1. Loosen the front axle wheel hub retainer. 2. With the vehicle in NEUTRAL, position on a hoist. 3.
Remove the front wheel and tire assembly. 4. Remove the components in the order indicated in the
illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5680
5. To install, reverse the removal procedure. 6. Verify the front axle lubricant level is to
specifications.
Item 1: Front Disc Brake Caliper Removal Note
1. CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang
suspended from the hose.
Remove the two bolts and position the disc brake caliper aside.
Item 2: Front Axle Wheel Hub Retainer Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose in the hub.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5681
Item 3: Tie-Rod End Nut Removal Note
1. Using the special tool, separate the tie-rod end from the knuckle.
Item 5: Upper Ball Joint Nut Removal Note
1. CAUTION: Do not allow the knuckle to hang freely. It is possible to overextend and internally
separate each inner CV joint from its housing.
Using the special tool, disconnect the upper ball joint from the knuckle
Item 6: Front Halfshaft Assembly Removal Note
1. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard
CV joint housing.
NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle
Using the special tool, disengage the left-hand CV joint housing from the side gear.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5682
2. CAUTION: Do not damage the axle shaft oil seal, the machined sealing surface on the inboard
CV joint housing, or the axle shaft splines.
CAUTION: Install a new retainer circlip on the outboard spline end of the axle shaft before
reseating the axle shaft in the differential side gear.
Pull the RH halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint
housing from the axle shaft.
3. Remove the outboard CV joint from the hub.
4. Remove the two inboard boot clamps.
5. Separate the CV joint from the CV housing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5683
6. Remove the stop ring.
7. Remove the snap ring.
8. Remove the CV joint.
9. Remove the inboard boot.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5684
10. Remove the two outboard boot clamps.
11. Remove the outboard CV boot. 12. If the CV joint is worn or damaged, install a new outboard
CV joint and shaft assembly.
Item 7: Front Axle Halfshaft Seal and Bearing Removal Note
1. Using the special tool, remove the halfshaft seal.
2. Using the special tool, remove the halfshaft bearing.
Item 7: Front Axle Halfshaft Seal and Bearing Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5685
1. Using the special tools, install the RH halfshaft bearing.
2. Using the special tools, install the LH halfshaft bearing.
3. Using the special tools, install the halfshaft seals.
Item 6: Front Halfshaft Assembly Installation Note
1. Lubricate the outboard CV joint.
1 Pack the outboard CV joint with 185 grams (6.53 oz) of grease. ^
One-third of the grease must be installed in the joint with the remainder placed in the boot.
2 Spread the remaining grease evenly inside the boot.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5686
2. Position the outboard halfshaft boot and the outboard boot clamps.
1 Position the boot.
2 Position the boot clamps.
3. Install the outboard CV boot clamps.
4. Position the inboard clamp and boot.
5. Install the CV joint and snap ring on the halfshaft.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5687
6. Install the stop ring.
7. Fill the inboard CV joint housing with 210 grams (7.41 oz) of grease.
^ One-half of the grease must be installed in the joint and the remainder placed in the boot.
8. Position the CV housing on the CV joint
9. Position the inboard halfshaft boot and clamp
1 Position the boot in the housing groove
2 Position the boot clamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Rear Axle Halfshafts, Bearings and Seals > Page 5688
10. Using the special tool, install the boot clamps
11. CAUTION: On the RH side, check the retainer circlip engagement after reseating the axle shaft
and after installing the halfshaft in the axle. On
the LH side, check the retainer circlip engagement after installing the halfshaft in the axle. When
seated, the retainer circlip will lock the axle shaft and the inboard CV joint housing to the axle.
Install a new retainer circlip
Item 2: Front Axle Wheel Hub Retainer Installation Note
1. CAUTION: Never use power tools to tighten the front axle wheel hub retainer.
Install a new front axle wheel hub retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking
Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5697
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5698
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5699
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5700
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking
Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5706
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5707
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5708
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5709
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5710
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-19-3 Date: 080929
Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5711
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5712
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5713
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5714
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Technical Service Bulletin # 08-19-3 Date: 080929
Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5715
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5716
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE
SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL
SEPARATE, RESULTING IN THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5717
Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor
Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
5718
Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise
Wheel Bearing: Customer Interest Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise > Page 5727
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise > Page 5728
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise > Page 5729
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 >
Drivetrain - Rear Axle Hub Bearing Noise
Wheel Bearing: All Technical Service Bulletins Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 >
Drivetrain - Rear Axle Hub Bearing Noise > Page 5735
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 >
Drivetrain - Rear Axle Hub Bearing Noise > Page 5736
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 >
Drivetrain - Rear Axle Hub Bearing Noise > Page 5737
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 5738
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tires are off of the ground.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the wheel and tire assembly.
Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire from the front wheel bearings. If movement exists, a new bearing must be
installed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Front
Special Tool(s)
1. On 4x4 vehicles, loosen the axle retainer nut
2. NOTE: The wheel speed sensor electrical connectors are located in the engine compartment
secured to the fender aprons
Disconnect the wheel speed sensor.
3. Remove the wheel and tire assembly.
4. To remove individual suspension components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5741
5. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5742
6. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and
table. 7. To install, reverse the removal procedure.
Item 1: Axle-to-Wheel Hub Nut Removal Note
1. Remove the nut and, using the special tool, separate the outboard CV joint from the wheel hub.
Item 2: Speed Sensor Harness Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5743
1. Detach the wheel speed sensor harness from the brake hose
Item 5: Brake Caliper, Pads and Anchor Plate Removal Note
1. CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose can
occur.
Position the caliper, pads and anchor plate aside
Item 10: Tie-Rod End-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod from the wheel knuckle
Item 11: Lower Ball Joint-to-Wheel knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle
Item 12: Upper Ball Joint-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5744
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
Item 27: Lower Arm Installation Note 1. Check and, if necessary, align the front end.
Item 24: Lower Arm-to-Frame Nut (forward mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 21: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Item 16: Upper Arm Installation Note 1. Check and, if necessary, align the front end.
Item 13: Wheel Knuckle Installation Note 1. Check and, if necessary, align the front end.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5745
Wheel Bearing: Service and Repair Rear
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5746
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5747
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5748
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5749
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5750
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Front Suspension
Axle-to-wheel hub nut ..........................................................................................................................
............................................. 250Nm (184 ft. lbs.)
Rear Suspension
Axle-to-wheel hub retainer nut
.........................................................................................................................................................
275 Nm (203 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 05-16-4 > Aug > 05 > Driveline Vibration/Boom Between 55 and 75 MPH
Drive/Propeller Shaft: Customer Interest Driveline - Vibration/Boom Between 55 and 75 MPH
TSB 05-16-4
08/22/05
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-3-7 to update the service procedure and to add a vehicle line.
ISSUE Some 2002-2005 4x4 Explorer 4dr/Mountaineer and 2003-2005 4x4 Aviator vehicles may
exhibit a vibration/drone/boom at 55-75 MPH (89-121 km/h). Electronic vibration analyzer (EVA)
readings will fall under 1st order rear driveshaft at 2700-3100 shaft RPM (45-52 Hertz).
ACTION If the condition is present in 3rd gear (with overdrive cancelled), and is isolated to the
driveline (not felt through the steering wheel), install a premium balanced driveshaft. Refer to the
following Service Procedure.
SERVICE PROCEDURE
NOTE
THIS TSB DOES NOT APPLY TO THE SOLID 4X2 DRIVESHAFT, IT ONLY APPLIES TO 4X4
WITH BOOT/SLIP JOINT IN THE MIDDLE OF THE DRIVESHAFT.
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Workshop Manual Section 100-02.
2. Remove skid plate, if equipped.
3. Remove the driveshaft flange bolts (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 05-16-4 > Aug > 05 > Driveline Vibration/Boom Between 55 and 75 MPH > Page 5764
4. Remove the transfer case rear output flange bolts (Figure 2).
NOTE
THE DRIVESHAFT FLANGE FITS TIGHTLY ON THE AXLE PINION FLANGE PILOT AND THE
TRANSFER CASE OUTPUT FLANGE. DO NOT HAMMER ON THE DRIVESHAFT OR ANY OF
ITS COMPONENTS TO DISCONNECT THE DRIVESHAFT FLANGES FROM THE MATING
FLANGES. PRY ONLY IN THE AREA SHOWN WITH A SUITABLE TOOL, TO DISCONNECT
THE DRIVESHAFT FLANGES.
5. Using a suitable tool, disconnect the driveshaft flanges and remove the driveshaft (Figure 3).
6. Measure the NEW driveshaft length from u-joint center to u-joint center. Refer to Step 6a or 6b.
a. Driveshafts measuring LESS than 1194 +/- 1.0 mm must be expanded as follows:
(1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice.
CAUTION
CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE.
(2) Grasp the shaft at the opposing flange with both hands and expand (by pulling) as required to
1194 +/- 1.0 mm.
NOTE
DO NOT USE A BAR OR SIMILAR DEVICE BETWEEN THE FLANGE AND CARDON JOINT.
b. Driveshafts measuring GREATER than 1194 +/- 1.0 mm must be compressed as follows:
(1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice.
CAUTION
CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE.
(2) Grasp the shaft at the opposing flange with both hands and compress (by pushing) together by
hand as required to 1194 +/- 1.0 mm.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 05-16-4 > Aug > 05 > Driveline Vibration/Boom Between 55 and 75 MPH > Page 5765
NOTE
DO NOT USE A HAMMER OR SIMILAR DEVICE. THIS MAY CAUSE DAMAGE TO THE SHAFT
FLANGE.
7. To install, align the driveshaft paint markings with companion flange markings, if present.
8. Coat the bolts with Threadlock And Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
NOTE
THE DRIVESHAFT FLANGES FITS TIGHTLY ON THE PINION FLANGE PILOTS. TO ENSURE
THE DRIVESHAFT FLANGES SEAT SQUARELY ON THE PINION FLANGES, TIGHTEN THE
DRIVESHAFT FLANGE BOLTS EVENLY IN ACROSS PATTERN.
9. Support the rear driveshaft.
10. Install flange bolts at rear axle flange by hand.
11. Install flange bolts at transfer case flange by hand.
12. Tighten all driveshaft flange bolts to 76 lb-ft (103 N.m).
13. Reinstall skid plate, if equipped.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-16-4 > Aug > 05 >
Driveline - Vibration/Boom Between 55 and 75 MPH
Drive/Propeller Shaft: All Technical Service Bulletins Driveline - Vibration/Boom Between 55 and 75
MPH
TSB 05-16-4
08/22/05
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-3-7 to update the service procedure and to add a vehicle line.
ISSUE Some 2002-2005 4x4 Explorer 4dr/Mountaineer and 2003-2005 4x4 Aviator vehicles may
exhibit a vibration/drone/boom at 55-75 MPH (89-121 km/h). Electronic vibration analyzer (EVA)
readings will fall under 1st order rear driveshaft at 2700-3100 shaft RPM (45-52 Hertz).
ACTION If the condition is present in 3rd gear (with overdrive cancelled), and is isolated to the
driveline (not felt through the steering wheel), install a premium balanced driveshaft. Refer to the
following Service Procedure.
SERVICE PROCEDURE
NOTE
THIS TSB DOES NOT APPLY TO THE SOLID 4X2 DRIVESHAFT, IT ONLY APPLIES TO 4X4
WITH BOOT/SLIP JOINT IN THE MIDDLE OF THE DRIVESHAFT.
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Workshop Manual Section 100-02.
2. Remove skid plate, if equipped.
3. Remove the driveshaft flange bolts (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-16-4 > Aug > 05 >
Driveline - Vibration/Boom Between 55 and 75 MPH > Page 5771
4. Remove the transfer case rear output flange bolts (Figure 2).
NOTE
THE DRIVESHAFT FLANGE FITS TIGHTLY ON THE AXLE PINION FLANGE PILOT AND THE
TRANSFER CASE OUTPUT FLANGE. DO NOT HAMMER ON THE DRIVESHAFT OR ANY OF
ITS COMPONENTS TO DISCONNECT THE DRIVESHAFT FLANGES FROM THE MATING
FLANGES. PRY ONLY IN THE AREA SHOWN WITH A SUITABLE TOOL, TO DISCONNECT
THE DRIVESHAFT FLANGES.
5. Using a suitable tool, disconnect the driveshaft flanges and remove the driveshaft (Figure 3).
6. Measure the NEW driveshaft length from u-joint center to u-joint center. Refer to Step 6a or 6b.
a. Driveshafts measuring LESS than 1194 +/- 1.0 mm must be expanded as follows:
(1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice.
CAUTION
CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE.
(2) Grasp the shaft at the opposing flange with both hands and expand (by pulling) as required to
1194 +/- 1.0 mm.
NOTE
DO NOT USE A BAR OR SIMILAR DEVICE BETWEEN THE FLANGE AND CARDON JOINT.
b. Driveshafts measuring GREATER than 1194 +/- 1.0 mm must be compressed as follows:
(1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice.
CAUTION
CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE.
(2) Grasp the shaft at the opposing flange with both hands and compress (by pushing) together by
hand as required to 1194 +/- 1.0 mm.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-16-4 > Aug > 05 >
Driveline - Vibration/Boom Between 55 and 75 MPH > Page 5772
NOTE
DO NOT USE A HAMMER OR SIMILAR DEVICE. THIS MAY CAUSE DAMAGE TO THE SHAFT
FLANGE.
7. To install, align the driveshaft paint markings with companion flange markings, if present.
8. Coat the bolts with Threadlock And Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
NOTE
THE DRIVESHAFT FLANGES FITS TIGHTLY ON THE PINION FLANGE PILOTS. TO ENSURE
THE DRIVESHAFT FLANGES SEAT SQUARELY ON THE PINION FLANGES, TIGHTEN THE
DRIVESHAFT FLANGE BOLTS EVENLY IN ACROSS PATTERN.
9. Support the rear driveshaft.
10. Install flange bolts at rear axle flange by hand.
11. Install flange bolts at transfer case flange by hand.
12. Tighten all driveshaft flange bolts to 76 lb-ft (103 N.m).
13. Reinstall skid plate, if equipped.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 5778
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: >
07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 5784
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Page 5785
Drive/Propeller Shaft: Specifications
Rear driveshaft flange yoke-to-transfer case bolts
.................................................................................................................................. 112 Nm (83 ft.
lbs.) Driveshaft-to-rear axle pinion flange bolts
............................................................................................................................................. 112 Nm
(83 ft. lbs.) Front driveshaft-to-front axle yoke bolts
.................................................................................................................................................. 18 Nm
(13 ft. lbs.) Front driveshaft constant velocity joint-to-transfer case flange bolts
...................................................................................................... 30 Nm (22 ft. lbs.) Front driveshaft
universal joint spider retaining bolt
................................................................................................................................ 19 Nm (14 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear
Drive/Propeller Shaft: Service and Repair Driveshaft Rear
Rear Driveshaft-4x4
Special Tool(s)
Material
1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the skid plate, if equipped.
3. Index-mark the driveshaft flange to the transfer case rear output flange.
4. Index-mark the driveshaft flange to the rear axle pinion flange. 5. Remove the components in the
order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear > Page 5788
6. To install, reverse the removal procedure.
Item 2 and 4: Driveshaft Flange Yoke Removal Note
1. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot and the transfer
case output flange. Never hammer on the
driveshaft or any of its components to disconnect the driveshaft flange from the mating flange. Pry
only in the area shown, with a suitable tool, to disconnect the driveshaft flange.
Using a suitable tool as shown, disconnect the driveshaft flange.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear > Page 5789
Item 5: Driveshaft Assembly Removal Note
1. Index-mark the driveshaft on both sides of the boot.
^ Install a new slip-yoke boot, if necessary.
Item 7 and 9: U-Joint Spider Removal Note
1. Position the driveshaft flange yoke in the special tool. Using the special tool, press out the
bearing cup. 2. If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed all
the way out. 3. Rotate the driveshaft flange yoke and press on the spider to remove the remaining
bearing cup.
Item 6 and 8: U-Joint Snap Ring Installation Note
1. Use the yellow snap rings supplied in the kit to install the U-joint. If difficulty is encountered with
the yellow snap rings, install the black snap
rings, as required.
Item 2 and 4: Driveshaft Flange Yoke Installation Note
1. Position the driveshaft and align the marks on the flanges.
Item 1 and 3: Driveshaft Flange Bolts Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear > Page 5790
1. CAUTION: If new bolts to retain the driveshaft to the axle and transfer case flanges are not
available, coat the threads of the original bolts with
threadlock and sealer.
To make sure that the driveshaft flanges seat squarely on the pinion and transmission flanges,
tighten the bolts evenly in a cross pattern as shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear > Page 5791
Drive/Propeller Shaft: Service and Repair Driveshaft Front
Front Driveshaft
Special Tool(s)
Removal and Installation
CAUTION: Always disconnect the front driveshaft from the axle first. Carefully pull the driveshaft
out of the CV joint housing. Otherwise, the weight of the driveshaft can pinch the boot between the
shaft and the boot can, and cause the boot to tear.
CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.
NOTE: The front driveshaft CV joint is not repairable.
1. With the vehicle in NEUTRAL, position on a hoist.
2. Remove the skid plate, if equipped
3. Index-mark the front axle pinion [range and the front driveshaft
4. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint.
5. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear > Page 5792
6. To install, reverse the removal procedure.
Item 7: U-Joint Spider Removal Note
1. Position the driveshaft in the special tool. Using the special tool, press out the bearing cup. 2. If
necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way out. 3.
Rotate the driveshaft and press on the spider to remove the remaining bearing cup.
Item 6: U-Joint Snap Ring Installation Note
1. Use the yellow snap rings supplied in the kit to install the U-joint. If difficulty is encountered with
the yellow snap rings, install the black snap
rings, as required.
Item 4: U-Joint Strap Installation Note
1. Verify that the U-joint bearing caps are seated in the pinion yoke flange before tightening the
strap bolts.
Item 3: U-Joint Bolt Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft Rear > Page 5793
1. NOTE: Install new U-joint bolts. If new bolts are not available, coat the threads of the original
bolts with threadlock and sealer.
Install the new U-joint bolts.
Item 2: CV Joint Installation Note
1. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the
factory. When housed correctly, the can will
appear as shown in the cut-away illustration (top box). Do not reseat the can in the CV joint
housing if the can's flange is above the CV joint housing as shown in the cut-away illustration
(bottom box). Install a new driveshaft.
Verify that the can flange is housed correctly in the CV joint housing as shown in the cut-away
illustration (top box). Install a new driveshaft if the can flange is not housed correctly.
Item 1: CV Joint Bolts Installation Note
1. CAUTION: Tighten the bolts evenly in a cross pattern in the sequence shown, or damage will
occur to the CV joint.
NOTE: Install new washers and bolts. If new bolts are not available, coat the threads of the original
bolts with threadlock and sealer.
Install the new washers and bolts. Tighten the bolts evenly in a cross pattern as shown.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair
Flex Plate: Service and Repair
Flexplate or Flywheel and Crankshaft Rear Seal
Special Tool(s)
1. Remove the transmission.
2. To remove individual components, carry out only the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Page
5797
3. Remove the components in the order indicated. 4. To install, reverse the removal procedure.
Item 5: Crankshaft Rear Oil Seal Removal Note
1. CAUTION: Avoid scratching or damaging the crankshaft rear oil seal running surface during
removal of the crankshaft rear oil seal.
Using the special tools, remove the crankshaft rear oil seal.
Item 5: Crankshaft Rear Oil Seal Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Page
5798
1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To
clean the-crankshaft rear sealing surface, use
extra-fine emery cloth or extra-fine steel wool with metal surface cleaner.
Lubricate the crankshaft rear oil seal with clean engine oil and install the special tool. ^
Lubricate the crankshaft rear oil seal with motor oil before installation.
2. Using the special tool, install the crankshaft rear oil seal.
Item 1: Flexplate Bolt Installation Note
1. Install the flexplate. Tighten the bolts in two stages in the sequence shown.
^ Stage 1: Tighten the bolts to 13 Nm (10 inch lbs.).
^ Stage 2: Tighten the bolts to 71 Nm (52 ft. lbs.).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5809
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5810
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: Customer Interest A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Control Module: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: All Technical Service Bulletins A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page
5826
View 151-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page
5827
Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams
Overdrive Switch: Diagrams
Transmission Control Switch (TCS) C/O
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 5836
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5840
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5841
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5842
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5843
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Speed sensor screws ..........................................................................................................................
....................................................... 14 Nm (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 5849
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed
Sensor > Page 5850
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed
Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed
Sensor > Page 5853
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed
Sensor > Page 5854
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft
Speed (OSS) Sensor
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft
Speed (OSS) Sensor > Page 5857
1. Remove the OSS sensor.
1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the OSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft
Speed (OSS) Sensor > Page 5858
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft
Speed (OSS) Sensor > Page 5859
1. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the transmission.
^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the TSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft
Speed (OSS) Sensor > Page 5860
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft
Speed (OSS) Sensor > Page 5861
1. Remove the intermediate shaft speed sensor.
1 Remove the intermediate shaft speed sensor screw.
2 Remove the intermediate shaft speed sensor from the transmission.
^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the intermediate shaft speed sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 solenoid body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5867
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5868
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5869
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5870
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5871
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5872
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5873
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5874
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5875
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5876
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5877
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5878
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5879
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5880
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5881
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5882
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5883
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5884
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5885
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5886
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5887
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 solenoid body. - The PCM uses the TFT signal to help determine shift
scheduling, torque converter clutch operation and pressure control requirements.
It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature.
The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift
schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits
torque converter clutch (TCC) operation at low transmission fluid temperatures and use to
determine pressure control (PC) solenoid operations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 5892
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information >
Specifications
Case: Specifications
Transfer case bolts ..............................................................................................................................
...................................................... 25 Nm (18 ft. lbs.) Transfer case to transmission bolts
...........................................................................................................................................................
41 Nm (30 ft. lbs.) Transfer case shift motor bolts
..............................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > Customer Interest: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and
3rd Gear
Control Module: Customer Interest A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder
in 2nd and 3rd Gear
Control Module: All Technical Service Bulletins A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 04-4-5 > Mar > 04 > Body Roof Rack Side Rail Paint Peeling
Roof Rack Frame: All Technical Service Bulletins Body - Roof Rack Side Rail Paint Peeling
Article No. 04-4-5
03/08/04
BODY - TRIM - PAINT PEEL-OFF - ROOF RACK SIDE RAIL
FORD: 2002-2004 EXPLORER
MERCURY: 2002-2004 MOUNTAINEER
ISSUE
Some 2002-2004 4DR Explorer and Mountaineer vehicles may exhibit paint peel on either roof rack
side rail.
ACTION
New service parts are now available to replace either affected side of the roof rack. Order Service
Kit 4L2Z-7855128-AA (RH) or 4L2Z-7855129-AA (LH). Refer to the following Service Procedure for
installation.
SERVICE PROCEDURE
NOTE
THE PROCEDURE IS THE SAME FOR RIGHT OR LEFT HAND SIDE. SEE (FIGURE 1) FOR
EXPLODED VIEW OF ASSEMBLY.
1. Remove front, center, and rear side rail caps by spreading apart from inboard side, and prying
outboard.
2. If equipped with crossbows, support unfastened end of crossbow to prevent damage to roof
panel. Remove both front and rear T-20 TORX head crossbow fasteners which are threaded into
the side rail.
3. Remove six (6) Phillips head screws which fasten rail to roof panel, two (2) each at front, center,
and rear.
4. Remove side rail(s).
5. Remove rubberized gasket at base of each attachment point, front, center and rear.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 04-4-5 > Mar > 04 > Body Roof Rack Side Rail Paint Peeling > Page 5915
6. Remove two (2) cargo tie-downs for each rail replaced, and transfer to new side rail.
7. Reverse procedures to install, torque side rail and crossbow fasteners to 3.2 +/- 0.3 N.m (28 +/2.5 lb-in).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040405A Replace Roof Rack Side 0.4 Hr.
Rail (One Rail)
040405B Replace Roof Rack Side 0.7 Hr.
Rails (Both Rails)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7855100 70
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 04-4-5 > Mar > 04 > Body Roof Rack Side Rail Paint Peeling > Page 5921
6. Remove two (2) cargo tie-downs for each rail replaced, and transfer to new side rail.
7. Reverse procedures to install, torque side rail and crossbow fasteners to 3.2 +/- 0.3 N.m (28 +/2.5 lb-in).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040405A Replace Roof Rack Side 0.4 Hr.
Rail (One Rail)
040405B Replace Roof Rack Side 0.7 Hr.
Rails (Both Rails)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7855100 70
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > Page 5922
View 151-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Technical Service Bulletins > Page 5923
Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 5928
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Page 5929
Fluid - Transfer Case: Service and Repair
Transfer Case Draining and Filling
1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed.
NOTE: The fluid level must be just below the fill plug.
Remove the fill plug and check the fluid level. ^
If the fluid is below the proper level, fill the transfer case with automatic transmission fluid.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5936
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four
Wheel Drive Indicator Lamp > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: Customer Interest A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and 3rd Gear
Control Module: All Technical Service Bulletins A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5955
View 151-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5956
Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations > Page 5961
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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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 5970
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5971
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5972
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5973
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5974
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5975
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5976
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5977
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5978
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5979
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5980
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5981
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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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 5982
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5983
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5984
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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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 5985
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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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 5986
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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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 5987
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 5988
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5989
Pressure Regulating Solenoid: Exploded Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 5990
29-3
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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 5991
Pressure Regulating Solenoid: Description and Operation
Pressure Control Solenoids (PCA, PCB, PCC)
The pressure control (PC) solenoids are a variable-force style (VFS) solenoid. The VFS-type
solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The line pressure tap is used to verify output pressure from PC A or PC B by turning either one off
while verifying the output from the other solenoid. The second pressure tap is used to verify the
output from the PC C solenoid.
There are three PC solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
The powertrain control module (PCM) varies the current to the PC solenoid.
The PCM has an adaptive learn strategy to electronically control the transmission which will
automatically adjust the shift feel. When the battery has been disconnected, or a new battery
installed, certain transmission operating parameters may be lost. The PCM must relearn these
parameters. During this learning process you may experience slightly firm shifts, delayed, or early
shifts. This operation is considered normal and will not affect the function of the transmission.
Normal operation will return once these parameters are stored by the PCM.
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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 5992
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
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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 5993
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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Information > Diagrams > Page 5994
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair
Shift Interlock Solenoid: Service and Repair
Removal and Installation
NOTE: Some 2002-2005 Explorer 4 Dr/Mountaineer vehicles may require a greater effort to move
the gear selector lever from drive to park. This may be due to a time delay with the brake shift
interlock pin retraction.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 2 fasteners supporting the instrument panel knee bolster from below the steering
column and remove the cover.
3. Remove the 3 fasteners supporting the steering column lower shroud and remove the cover.
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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 Interlock Solenoid > Component Information > Service
and Repair > Page 5998
4. Remove the 3 wiring bundle carrier fasteners from the bottom of the steering column to allow
movement while removing the brake shift interlock
switch. It may be necessary to release the connectors from the multifunction switch.
5. Remove the brake shift interlock bolts.
6. Pull the brake shift interlock tab on the bottom of the column downward to help free the brake
shift interlock from the column housing.
7. Break the 2 side tabs off the brake shift interlock by the white wiring connector.
8. Push the locking tab on the white connector towards the wiring to release the connector from the
brake shift interlock. Be careful not to damage
the connector or wiring. If the connector does not free easily, a very small flat screwdriver may be
used to help lift the locking tab.
9. Connect the wiring to the new brake shift interlock. Make sure all clips are fully engaged to
prevent the connector from pulling free.
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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 Interlock Solenoid > Component Information > Service
and Repair > Page 5999
10. Position the brake shift interlock onto the steering column and reinstall fasteners.
11. Check brake shift interlock function. With the key in the accessory or run position, press the
brake pedal. The brake shift interlock pin should
retract on brake application and spring up 1 second after releasing the brake pedal. Repeat several
times.
12. Reinstall the fasteners to connect the wiring bundle carrier to the steering column. Make sure
all connections to the multifunction switch unit are
secured correctly.
13. Assemble the steering column in reverse order. Make sure the rubber gap hider around the
shift lever is correctly seated on the shroud.
14. Cycle the shift lever from park to drive and drive back to park several times to verify improved
shift effort.
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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 > Locations
Shift Solenoid: Locations
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Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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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 6005
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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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 6006
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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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 6007
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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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 6008
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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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 6009
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6010
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6011
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6012
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6013
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6014
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6015
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6016
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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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 6017
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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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 6018
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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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 6019
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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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 6020
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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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 6021
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Diagram Information and Instructions > Page 6022
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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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 6023
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 6024
Shift Solenoid: Exploded Views
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Diagram Information and Instructions > Page 6025
29-3
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Page 6026
Shift Solenoid: Description and Operation
Shift Solenoids (SSA, SSB, SSC, SSD)
Four On/Off shift solenoids allow the powertrain control module (PCM) to control shift scheduling.
The solenoids are three-way, normally open style. The shift solenoids SSA, SSB, SSC, and SSD
provide gear selection of first through fifth and reverse gears by directing PC pressures to the
appropriate elements. Coast braking and manual gears are also controlled by the shift solenoids.
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Page 6027
Shift Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
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Page 6028
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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Page 6029
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Locations
Torque Converter Clutch Solenoid: Locations
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6035
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6036
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 6037
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Information > Diagrams > Diagram Information and Instructions > Page 6038
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Information > Diagrams > Diagram Information and Instructions > Page 6039
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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Information > Diagrams > Diagram Information and Instructions > Page 6040
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Symbols Part 2
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Information > Diagrams > Diagram Information and Instructions > Page 6042
Symbols Part 3
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Information > Diagrams > Diagram Information and Instructions > Page 6043
Symbols Part 4
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Information > Diagrams > Diagram Information and Instructions > Page 6044
Symbols Part 5
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Information > Diagrams > Diagram Information and Instructions > Page 6045
Systems Overview
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Information > Diagrams > Diagram Information and Instructions > Page 6046
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 6047
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Information > Diagrams > Diagram Information and Instructions > Page 6048
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Information > Diagrams > Diagram Information and Instructions > Page 6049
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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Information > Diagrams > Diagram Information and Instructions > Page 6050
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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Information > Diagrams > Diagram Information and Instructions > Page 6051
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Information > Diagrams > Diagram Information and Instructions > Page 6052
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Information > Diagrams > Diagram Information and Instructions > Page 6053
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Information > Diagrams > Diagram Information and Instructions > Page 6054
Torque Converter Clutch Solenoid: Exploded Views
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Information > Diagrams > Diagram Information and Instructions > Page 6055
29-3
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Information > Diagrams > Page 6056
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is a pulse width modulating type solenoid which is used
to control the apply and release of the TCC.
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Information > Diagrams > Page 6057
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be
notified that they may experience slightly different upshifts (either soft or firm) and this is a
temporary condition and will eventually return to normal operating condition.
1. Disconnect the battery ground cable. 2. With the vehicle in PARK, position on a hoist. 3. Remove
the components in the order indicated in the illustration and table.
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Information > Diagrams > Page 6058
4. To install, reverse the removal procedure. 5. Verify that the shift cable is adjusted correctly.
Item 13: Solenoid Body O-Ring Seals Installation Note
1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean
automatic transmission fluid.
Item 10 and 11: Solenoid Body Screws Installation Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not
damaged. If damaged, a transmission leak may
occur.
Install the solenoid body. Tighten the screws in the sequence shown.
Item 6: Transmission Fluid Pan Installation Note
1. Install the transmission fluid pan and gasket and loosely install the screws.
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Information > Diagrams > Page 6059
Item 5: Transmission Fluid Pan Screws Installation Note
1. Tighten the screws in a crisscross sequence.
Item 4: Solenoid Body Harness Electrical Connector Installation Note
1. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the
specification.
NOTE: Always install new O-ring seals on the vehicle harness connector.
NOTE: Clean the area around the connector to prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the transmission connector and connect the connector.
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Information > Diagrams
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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 > Technical Service Bulletins > Customer Interest: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder in 2nd and
3rd Gear
Control Module: Customer Interest A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
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Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-21-4 > Oct > 05 > A/T, Drivetrain - Shudder
in 2nd and 3rd Gear
Control Module: All Technical Service Bulletins A/T, Drivetrain - Shudder in 2nd and 3rd Gear
TSB 05-21-4
10/31/05
SHUDDER IN 2ND AND 3RD GEAR ON ACCELERATION - 4X4 VEHICLES WITHOUT
ADVANCETRAC
FORD: 2002-2003 Explorer
ISSUE Some 2002-2003 Explorer 4X4 vehicles without AdvanceTrac (Interactive Vehicle
Dynamics - IVD) equipped with an automatic transmission may exhibit a shudder in 2nd and 3rd
gear on acceleration. This condition may be more pronounced when the vehicle is under load.
ACTION Replace the 4X4 control module following the procedure in Workshop Manual Section
308-07A. Refer to the Part Application Table for the correct part number to install.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052104A 2002-2003 Explorer 4X4: 0.7 Hr.
Replace The 4X4 Control Module Includes Time For Road Test To Verify Concern (Do Not Use
With 7453D, 7453D1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7E453 42
Disclaimer
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Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
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Instruments - False Parking Aid Warnings > Page 6085
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
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Instruments - False Parking Aid Warnings > Page 6086
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
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Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings > Page 6087
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings > Page 6088
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings > Page 6094
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings > Page 6095
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings > Page 6096
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 05-6-4 > Apr > 05 >
Instruments - False Parking Aid Warnings > Page 6097
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > Page 6098
View 151-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Technical Service Bulletins > Page 6099
Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams
Overdrive Switch: Diagrams
Transmission Control Switch (TCS) C/O
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > Page 6108
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6112
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6113
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor
Special Tools
Special Tool(s)
1. On 4x4 vehicles, remove the front driveshaft. 2. On 4x2 vehicles, with the vehicle in NEUTRAL,
position on a hoist. 3. It is not necessary to remove the shift cable and bracket from the
transmission. 4. Remove the components in the order indicated in the illustration and table.
5. To install, reverse the removal procedure 6. Refill the transmission with the specified fluid. 7.
Verify that the shift cable is adjusted correctly.
Item 1: TR Sensor Electrical Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6114
1. Move the rubber boot back to gain access to the connector.
2. Disconnect the digital TR sensor connector.
Item 6: TR Sensor Installation Note
1. CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage
to the sensor.
Install the digital TR sensor and loosely install the screws.
Item 5: TR Sensor Screws Installation Note
1. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating
sequence.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 6115
Item 1: TR Sensor Electrical Connector Installation Note
1. Connect the digital TR sensor connector.
2. Move the rubber boot back over the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Speed sensor screws ..........................................................................................................................
....................................................... 14 Nm (10 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 6121
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Intermediate Shaft Speed Sensor > Page 6122
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed Sensor > Page 6125
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Intermediate Shaft Speed Sensor > Page 6126
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 6129
1. Remove the OSS sensor.
1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the transmission.
^ Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the OSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 6130
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 6131
1. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the transmission.
^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the TSS sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 6132
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
NOTE: Lubricate the sensor O-ring with petroleum jelly prior to installing the sensor.
1. On 4x4 vehicles, remove the front driveshaft. 2. For 4x2 vehicles, with the vehicle in PARK,
position on a hoist.
3. Remove the shift cable and bracket. 4. Remove the components in the order indicated in the
illustration and table.
5. To install, reverse the removal procedure.
Item 3: Speed Sensor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Output Shaft Speed (OSS) Sensor > Page 6133
1. Remove the intermediate shaft speed sensor.
1 Remove the intermediate shaft speed sensor screw.
2 Remove the intermediate shaft speed sensor from the transmission.
^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring.
Item 3: Speed Sensor Installation Note
1. Inspect and lubricate the O-ring with petroleum jelly.
1 Install the intermediate shaft speed sensor into the transmission.
2 Tighten the screw.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 solenoid body.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6139
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6140
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6141
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6142
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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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 6143
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6144
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6145
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6146
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6147
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6148
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6149
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6150
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6151
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6152
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6153
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6154
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6155
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6156
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6157
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6158
29-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6159
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 solenoid body. - The PCM uses the TFT signal to help determine shift
scheduling, torque converter clutch operation and pressure control requirements.
It sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature.
The PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift
schedule is compensated when the transmission fluid temperature is cold. The PCM also inhibits
torque converter clutch (TCC) operation at low transmission fluid temperatures and use to
determine pressure control (PC) solenoid operations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 > Page 6164
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Sensor/Switch > Component Information > Locations
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking
Sensor/Switch > Component Information > Locations > Page 6170
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed
Sensor > Component Information > Locations
View 151-34
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed
Sensor > Component Information > Locations > Page 6177
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations
View 151-13
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6181
Electronic Brake Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6182
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6183
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
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: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
NOTE: When installing a new ABS module it must be configured (using vehicle as-built data) and
calibrated. Follow the scan tool directions for the configuration and calibration procedures.
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table. 3. To install, reverse
the removal procedure.
Item 1: Harness Connector Removal Note
1. Disconnect the electrical connector by rotating the protective cover.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
HCU bracket bolts ...............................................................................................................................
.................................................... 17 Nm (13 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6187
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)
Removal and Installation
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: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
1. Remove the battery tray.
2. NOTE: 4-channel anti-lock brake system (ABS) with stability assist shown, 3-channel ABS
similar.
Remove the parts in the order indicated in the following illustrations and tables.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6188
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 6189
3. To install, reverse the removal procedure.
Item 4: HCU Bracket Nuts Removal Note
1. Raise and support the vehicle.
Item 5: HCU Assembly Removal Note
1. Lower the vehicle.
Item 6, 3 and 2: Brake Tube Fitting Installation Note
1. Bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Accelerometer
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 1: Floor Console-Rear Removal Note 1. If equipped, remove the floor console-rear.
Item 2: Harness Connector Removal Note 1. Fold back the carpeting flap to gain access to the
accelerometer connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Removal and Installation
NOTE: The steering wheel rotation sensor is part of the clockspring assembly and is not serviced
separately.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations
View 151-22
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 6199
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-26-3 >
Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Wheel Speed Sensor: Customer Interest Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-26-3 >
Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6208
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 03-26-3 >
Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6209
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's
C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6215
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: >
03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6216
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Technical Service Bulletins > Page 6217
Wheel Speed Sensor: Specifications
Front
Wheel speed sensor wire retaining bolt
............................................................................................................................................... 8 Nm
(71 inch lbs.) Wheel speed sensor bolt ...............................................................................................
....................................................................... 8 Nm (71 inch lbs.)
Rear
Wheel speed sensor bolt .....................................................................................................................
.................................................. 27 Nm (20 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Left front
View 151-56
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Left front > Page 6220
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left front > Page 6223
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left front > Page 6224
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left front > Page 6225
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Front Wheel Speed Sensor and Sensor Ring
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the front wheel and tire assembly. 3. Remove
the components in the order indicated in the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 6228
4. To install, reverse the removal procedure.
Item 2: Front Disc Brake Caliper Anchor Plate, Caliper, and Pads Removal Note
1. CAUTION: When removing the front disc brake components, never allow them to hang from the
brake hose.
Using mechanic's wire, secure the front brake components.
Item 3: Front Disc Removal Note 1. Match mark the front disc and front wheel hub flange before
removing the front disc.
Item 4: Harness Connector Removal Note
1. NOTE: The harness connector is located in the engine compartment secured to the fender
apron.
Lower the vehicle.
Item 5: Harness Retainers Removal Note 1. Raise the vehicle on a hoist.
Item 8: Sensor Ring Removal Note 1. The sensor ring is integral to the front wheel hub and bearing
assembly and cannot be serviced.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 6229
Wheel Speed Sensor: Service and Repair Sensor, Rear
Rear Wheel Speed Sensor and Sensor Ring
Removal and Installation
1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. On vehicles with
3-channel ABS, remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure. 5. On vehicles with 4-channel ABS, remove the
components in the order indicated in the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 6230
6. To install, reverse the removal procedure.
Item 5: Sensor Ring Removal Note 1. On vehicles with 3-channel ABS, the sensor ring is attached
to the ring gear and must be removed from the rear differential case. 2. On vehicles with 4-channel
ABS, the sensor ring is attached to the rear axle shaft.
Item 4: O-Ring Installation Note 1. Install a new O-ring.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Locations
View 151-23
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Locations > Page 6234
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Locations > Page 6235
Yaw Rate Sensor: Service and Repair
Yaw Rate Sensor
Removal and Installation
NOTE: The yaw rate sensor is located within the same component as the lateral and longitudinal
accelerometer and must be installed as an assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair
Brake Bleeding: Service and Repair
Brake System Bleeding
Special Tool(s)
Material
Master Cylinder Bleeding 1. Connect one end of a clear, flexible hose to the master cylinder
bleeder screw. Submerge the other end in a container partially filled with the
specified brake fluid.
2. Have an assistant pump and then hold firm pressure on the brake pedal. 3. Open the master
cylinder bleeder screw until brake fluid flows into the container. 4. When the fluid stops flowing,
close the bleeder screw. 5. Repeat Steps 2-4 until there are no air bubbles in the brake fluid. 6.
Have an assistant pump and then hold firm pressure on the brake pedal. 7. Loosen a master
cylinder tube fitting at the anti-lock brake hydraulic control unit. 8. When fluid stops flowing from the
fitting, tighten the fitting. 9. Repeat Steps 6-8 until there are no air bubbles in the brake fluid.
10. Repeat Steps 6-9 on the remaining master cylinder tube fitting.
Brake Caliper Bleeding
NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened
part of the system.
1. Connect one end of a clear flexible hose to the caliper screw. Submerge the other end in a
container partially filled with the specified brake fluid. 2. Have an assistant pump and then hold firm
pressure on the brake pedal. 3. Open the caliper bleeder screw until brake fluid flows into the
container. 4. When fluid stops flowing, close the bleeder screw. 5. Repeat previous three steps until
there are no air bubbles in the brake fluid.
Anti-Lock Brake System Hydraulic Control Unit Bleeding
NOTE: This procedure is only required when a new hydraulic control unit is installed.
1. Connect the scan tool and follow the ABS system bleed instructions. 2. Use the caliper bleed
procedure to bleed the system. Begin at the RH rear caliper.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
General Specifications > Page 6243
Brake Pedal Assy: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 6244
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions
Brake Pedal Assy: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6247
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6248
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6249
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6250
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6251
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6252
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6253
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6254
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6255
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6256
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6257
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6258
Brake Pedal Assy: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6259
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6260
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6261
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6262
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6263
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6264
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6265
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6266
Brake Pedal Assy: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6267
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6268
Brake Pedal Assy: Electrical Diagrams
Adjustable Pedal
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
127-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6269
127-2
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Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6270
127-3
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Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams >
Diagram Information and Instructions > Page 6271
127-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page
6272
Brake Pedal Assy: Service and Repair
Brake Pedal
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the following illustration and table. 3. To install
reverse the removal procedure.
Item 9: Pedal and Bracket Assembly Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page
6273
1. Remove the wiper arms.
^ Raise the wiper arm to the vertical position, then pull outward to release the retainer.
2. Remove the cowl grille.
^ The grille is secured with 14 spring clips. Carefully pry the grille upward to release the clips.
3. Remove the instrument panel support bolt. 4. Remove the front console.
5. Remove the four instrument panel support bracket screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page
6274
6. Remove the door scuff plates.
7. Remove the retainer and the cowl panels.
8. Remove the finish panels.
9. Remove the caps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page
6275
10. Remove the assist handles.
11. Remove the moldings.
12. Remove the defroster grille.
13. Remove the instrument panel support bolts.
14. Remove the screws and the finish panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page
6276
15. Disconnect the wiring harness connector.
16. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate
shaft is disconnected or damage to the clockspring
can result. If there is evidence that the steering column shaft has rotated, the clockspring must be
removed and recentered.
Secure the steering wheel to prevent it from rotating.
17. Remove the bolt and separate the steering shafts.
18. Remove the instrument panel support bolts.
19. Pull the instrument panel approximately one inch away from the dash panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > General Specifications > Page 6282
Brake Caliper: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front
Brake Caliper: Service and Repair Front
Brake Caliper-Front
1. Remove the disc brake caliper. 2. Secure the disc brake caliper in a vise.
3. NOTE: Do not hone the piston bores. If the bores are excessively scored or corroded, install a
new brake disc caliper.
Disassemble the components in the order indicated in the following illustration and table.
4. To assemble, reverse the disassembly procedure.
Item 4: Piston Disassembly Note
CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the
piston.
1. Place a piece of wood in the caliper. Remove the piston by applying moderate air pressure
through the bleeder screw port.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6285
Brake Caliper: Service and Repair Rear
Brake Caliper-Rear
Special Tools
1. Remove the disc brake caliper. 2. Secure the disc brake caliper in a vise.
3. NOTE: Do not hone the piston bores. If the bores are excessively scored or corroded, install a
new brake disc caliper.
Disassemble the components in the order indicated in the following illustration and table.
4. To assemble, reverse the disassembly procedure.
Item 3: Piston Disassembly Note
CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the
piston.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 6286
1. Place a piece of wood in the caliper. Remove the piston by applying moderate air pressure
through the bleeder screw port.
Item 4: Seal Kit Assembly Note
1. Use the special tools to install the dust boot.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > General Specifications > Page 6291
Brake Pad: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > General Specifications > Page 6296
Brake Rotor/Disc: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair
Brake Bleeding: Service and Repair
Brake System Bleeding
Special Tool(s)
Material
Master Cylinder Bleeding 1. Connect one end of a clear, flexible hose to the master cylinder
bleeder screw. Submerge the other end in a container partially filled with the
specified brake fluid.
2. Have an assistant pump and then hold firm pressure on the brake pedal. 3. Open the master
cylinder bleeder screw until brake fluid flows into the container. 4. When the fluid stops flowing,
close the bleeder screw. 5. Repeat Steps 2-4 until there are no air bubbles in the brake fluid. 6.
Have an assistant pump and then hold firm pressure on the brake pedal. 7. Loosen a master
cylinder tube fitting at the anti-lock brake hydraulic control unit. 8. When fluid stops flowing from the
fitting, tighten the fitting. 9. Repeat Steps 6-8 until there are no air bubbles in the brake fluid.
10. Repeat Steps 6-9 on the remaining master cylinder tube fitting.
Brake Caliper Bleeding
NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened
part of the system.
1. Connect one end of a clear flexible hose to the caliper screw. Submerge the other end in a
container partially filled with the specified brake fluid. 2. Have an assistant pump and then hold firm
pressure on the brake pedal. 3. Open the caliper bleeder screw until brake fluid flows into the
container. 4. When fluid stops flowing, close the bleeder screw. 5. Repeat previous three steps until
there are no air bubbles in the brake fluid.
Anti-Lock Brake System Hydraulic Control Unit Bleeding
NOTE: This procedure is only required when a new hydraulic control unit is installed.
1. Connect the scan tool and follow the ABS system bleed instructions. 2. Use the caliper bleed
procedure to bleed the system. Begin at the RH rear caliper.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > General Specifications > Page 6305
Brake Caliper: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front
Brake Caliper: Service and Repair Front
Brake Caliper-Front
1. Remove the disc brake caliper. 2. Secure the disc brake caliper in a vise.
3. NOTE: Do not hone the piston bores. If the bores are excessively scored or corroded, install a
new brake disc caliper.
Disassemble the components in the order indicated in the following illustration and table.
4. To assemble, reverse the disassembly procedure.
Item 4: Piston Disassembly Note
CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the
piston.
1. Place a piece of wood in the caliper. Remove the piston by applying moderate air pressure
through the bleeder screw port.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6308
Brake Caliper: Service and Repair Rear
Brake Caliper-Rear
Special Tools
1. Remove the disc brake caliper. 2. Secure the disc brake caliper in a vise.
3. NOTE: Do not hone the piston bores. If the bores are excessively scored or corroded, install a
new brake disc caliper.
Disassemble the components in the order indicated in the following illustration and table.
4. To assemble, reverse the disassembly procedure.
Item 3: Piston Disassembly Note
CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the
piston.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 6309
1. Place a piece of wood in the caliper. Remove the piston by applying moderate air pressure
through the bleeder screw port.
Item 4: Seal Kit Assembly Note
1. Use the special tools to install the dust boot.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications > Capacity Specifications
Brake Fluid: Capacity Specifications
Fill to the line on the reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications > Capacity Specifications > Page 6314
Brake Fluid: Fluid Type Specifications
Brake fluid ............................................................................................................................................
...................................................................... DOT 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 6318
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Locations > Primary Brake Pressure Sensor
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Locations > Primary Brake Pressure Sensor > Page 6323
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Diagrams > Primary
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Diagrams > Primary > Page 6326
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > General Specifications > Page 6331
Brake Hose/Line: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
HCU bracket bolts ...............................................................................................................................
.................................................... 17 Nm (13 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6335
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)
Removal and Installation
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: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
1. Remove the battery tray.
2. NOTE: 4-channel anti-lock brake system (ABS) with stability assist shown, 3-channel ABS
similar.
Remove the parts in the order indicated in the following illustrations and tables.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6336
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 6337
3. To install, reverse the removal procedure.
Item 4: HCU Bracket Nuts Removal Note
1. Raise and support the vehicle.
Item 5: HCU Assembly Removal Note
1. Lower the vehicle.
Item 6, 3 and 2: Brake Tube Fitting Installation Note
1. Bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > General Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > General Specifications > Page 6342
Brake Master Cylinder: Specifications Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 6343
Brake Master Cylinder: Service and Repair
Brake Master Cylinder and Brake Booster
1. Disconnect the battery ground cable.
2. NOTE: IVD vehicle shown, non-IVD vehicle similar.
Remove the components in the order indicated in the illustration and table.
3. To install, reverse the removal procedure. 4. Bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 6344
Item 10: Brake Booster Nuts Removal Note
1. NOTE: Use new nuts when installing the brake booster.
Remove the brake booster nuts.
Item 11: Brake Booster Removal Note
1. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
View 151-38
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations > Page 6349
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection
Vacuum Brake Booster: Testing and Inspection
Brake Booster
Inspect the brake booster for the following:
- excessive corrosion or damage
- vacuum connections for leakage
- vacuum hoses for kinks or leakage
- brake booster check valve for correct operation
Changes in the brake pedal feel or travel are indicators that something could be wrong in the brake
system. Go to Symtom Chart for abnormal conditions diagnosis. See: Testing and
Inspection/Symptom Related Diagnostic Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 6354
Vacuum Brake Booster: Service and Repair
Brake Master Cylinder and Brake Booster
1. Disconnect the battery ground cable.
2. NOTE: IVD vehicle shown, non-IVD vehicle similar.
Remove the components in the order indicated in the illustration and table.
3. To install, reverse the removal procedure. 4. Bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 6355
Item 10: Brake Booster Nuts Removal Note
1. NOTE: Use new nuts when installing the brake booster.
Remove the brake booster nuts.
Item 11: Brake Booster Removal Note
1. Disconnect the brake pedal to power brake booster push rod.
1 Remove the self-locking pin.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 6356
2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin.
3 Remove the brake booster push rod bushing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Testing and Inspection
Vacuum Brake Booster Check Valve: Testing and Inspection
Check Valve
The function of the brake booster check valve is to allow manifold vacuum to enter the brake
booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full
throttle operation.
To test the function of the brake booster check valve: ^
Start and run the engine for at least 10 seconds.
^ Operate the brake pedal to check for power assist.
^ Disconnect the vacuum booster hose from the brake booster check valve. Do not remove the
brake booster check valve from the brake booster.
^ There should be enough vacuum retained in the brake booster for at least one more
power-assisted brake operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations
View 151-13
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6364
Electronic Brake Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6365
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6366
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
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: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
NOTE: When installing a new ABS module it must be configured (using vehicle as-built data) and
calibrated. Follow the scan tool directions for the configuration and calibration procedures.
1. Disconnect the battery ground cable.
2. Remove the components in the order indicated in the illustration and table. 3. To install, reverse
the removal procedure.
Item 1: Harness Connector Removal Note
1. Disconnect the electrical connector by rotating the protective cover.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6371
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 6376
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Diagrams > Primary
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Diagrams > Primary > Page 6379
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations
View 151-12
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking
Sensor/Switch > Component Information > Locations > Page 6383
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations
View 151-34
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations > Page 6387
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Accelerometer
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 1: Floor Console-Rear Removal Note 1. If equipped, remove the floor console-rear.
Item 2: Harness Connector Removal Note 1. Fold back the carpeting flap to gain access to the
accelerometer connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
View 151-38
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations > Page 6394
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Removal and Installation
NOTE: The steering wheel rotation sensor is part of the clockspring assembly and is not serviced
separately.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
View 151-22
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6401
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: >
03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Wheel Speed Sensor: Customer Interest Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: >
03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6410
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: >
03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6411
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set
Wheel Speed Sensor: All Technical Service Bulletins Brakes - ABS Lamp ON/DTC's
C1235/C1236/C1237 Set
Article No. 03-26-3
01/12/04
BRAKES - ABS LAMP ILLUMINATED AND DTC C1235, C1236, C1237 - VEHICLES WITH
DIFFERENTIAL - MOUNTED REAR WHEEL SPEED SENSOR
FORD: 2002-2004 EXPLORER
LINCOLN: 20Q3-2004 AVIATOR
MERCURY: 2002-2004 MOUNTAINEER
ISSUE Some vehicles may exhibit an Anti-Lock Brake System (ABS) warning lamp illuminated with
Diagnostic Trouble Codes (DTCs) C1235, C1236 and/or C1237 (Wheel Speed RR Input Signal
Missing/Wheel Speed LR Input Signal Missing/Rear Wheel Speed Sensor Output Failure) stored in
memory. This may be due to an intermittently functioning differential-mounted Rear Wheel Speed
Sensor.
ACTION To service, refer to the following diagnostic and repair procedure.
NOTE
THIS TSB ONLY APPLIES TO VEHICLES WITH DTCS C1235, C1236 AND/OR C1237. FOR ALL
OTHER DTC'S, REFER TO THE APPROPRIATE WORKSHOP MANUAL.
NOTE
THIS TSB DOES NOT APPLY TO VEHICLES EQUIPPED WITH ADVANCETRAC (STABILITY
ASSIST / IVD).
SERVICE PROCEDURE
1. Retrieve Continuous ABS DTC(s).
2. If C1235, C1236 and/or C1237 are present, turn ignition OFF and replace the
differential-mounted Rear Wheel Speed Sensor.
a. Raise vehicle on hoist so that the bottom of the rear differential is at head level.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6417
b. Stand slightly in front of the rear differential pinion flange, facing the rear of the vehicle (Figure
1).
c. Reach up and over the passenger side of the differential housing to access sensor.
d. Remove the hold-down bolt and remove sensor from differential housing (3/8" socket).
e. Unlatch red locking tab on the top of the electrical connector by sliding it away from the sensor,
then release connector latch and disconnect connector from sensor.
f. Install new sensor and torque hold-down bolt to 27 N.m (20 lb-ft).
g. Connect the electrical connector to the sensor.
NOTE
IT IS NO LONGER NECESSARY TO APPLY F8AZ-19G208-AA GREASE TO THE ELECTRICAL
CONNECTOR AS PREVIOUSLY RECOMMENDED.
3. Clear Continuous ABS DTC(s).
4. Verify repair.
NOTE
THE ABS SYSTEM CONFIRMS REAR WHEEL SPEED SENSOR SIGNAL INPUT BASED ON
SEVERAL WHEEL REVOLUTIONS ABOVE 24 KM/H (15 MPH). DRIVE VEHICLE FOR AT LEAST
75 FEET AT OR ABOVE 15 MPH. IF WHEEL SPEED SIGNAL INPUT IS MISSING THE ABS
LIGHT WILL ILLUMINATE.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032603A Replace The Differential 0.5 Hr.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed
Sensor: > 03-26-3 > Jan > 04 > Brakes - ABS Lamp ON/DTC's C1235/C1236/C1237 Set > Page 6418
Mount Rear Wheel Speed Sensor (Includes Time To Check For Codes Replace Sensor And Clear
Codes)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9E731 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Technical Service Bulletins > Page 6419
Wheel Speed Sensor: Specifications
Front
Wheel speed sensor wire retaining bolt
............................................................................................................................................... 8 Nm
(71 inch lbs.) Wheel speed sensor bolt ...............................................................................................
....................................................................... 8 Nm (71 inch lbs.)
Rear
Wheel speed sensor bolt .....................................................................................................................
.................................................. 27 Nm (20 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Left front
View 151-56
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Left front > Page 6422
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left front > Page 6425
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left front > Page 6426
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left front > Page 6427
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Front Wheel Speed Sensor and Sensor Ring
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the front wheel and tire assembly. 3. Remove
the components in the order indicated in the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6430
4. To install, reverse the removal procedure.
Item 2: Front Disc Brake Caliper Anchor Plate, Caliper, and Pads Removal Note
1. CAUTION: When removing the front disc brake components, never allow them to hang from the
brake hose.
Using mechanic's wire, secure the front brake components.
Item 3: Front Disc Removal Note 1. Match mark the front disc and front wheel hub flange before
removing the front disc.
Item 4: Harness Connector Removal Note
1. NOTE: The harness connector is located in the engine compartment secured to the fender
apron.
Lower the vehicle.
Item 5: Harness Retainers Removal Note 1. Raise the vehicle on a hoist.
Item 8: Sensor Ring Removal Note 1. The sensor ring is integral to the front wheel hub and bearing
assembly and cannot be serviced.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6431
Wheel Speed Sensor: Service and Repair Sensor, Rear
Rear Wheel Speed Sensor and Sensor Ring
Removal and Installation
1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. On vehicles with
3-channel ABS, remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure. 5. On vehicles with 4-channel ABS, remove the
components in the order indicated in the following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6432
6. To install, reverse the removal procedure.
Item 5: Sensor Ring Removal Note 1. On vehicles with 3-channel ABS, the sensor ring is attached
to the ring gear and must be removed from the rear differential case. 2. On vehicles with 4-channel
ABS, the sensor ring is attached to the rear axle shaft.
Item 4: O-Ring Installation Note 1. Install a new O-ring.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
View 151-23
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 6436
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations > Page 6437
Yaw Rate Sensor: Service and Repair
Yaw Rate Sensor
Removal and Installation
NOTE: The yaw rate sensor is located within the same component as the lateral and longitudinal
accelerometer and must be installed as an assembly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 6445
Ignition Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 6446
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Diagrams > Page 6447
Ignition Switch: Service and Repair
IGNITION LOCK CYLINDER
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Ignition Lock Cylinder Removal Note
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 6451
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6456
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6457
Starter Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6458
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Battery Eye Function/Charging/Service
Battery: Technical Service Bulletins Battery - Battery Eye Function/Charging/Service
TSB 07-5-8
03/19/07
BATTERY SERVICE - OPERATION OF BATTERY EYE - CHARGING SERVICE TIPS
FORD: 1999-2003 Escort 2000-2006 Taurus 2000-2007 Crown Victoria, Focus, Mustang
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 2000-2003
Windstar 2000-2004 Explorer Sport 2000-2006 Excursion 2000-2007 E-Series, Expedition,
Explorer, F-150, F-250 Light Duty, F-53 Motorhome Chassis, F-Super Duty, Ranger 2001-2003
Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004-2006 Freestar 2005-2007 Escape
Hybrid 2007 Edge 2000-2007 F-650, F-750 2006 Low Cab Forward
LINCOLN: 1998-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007
MKZ 2000-2007 Navigator 2002 Blackwood 2003-2005 Aviator 2006-2007 Mark LT, Mark LT 2007
MKX
MERCURY: 1999-2002 Cougar 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego
2006-2007 Milan 2000-2002 Villager 2000-2007 Mountaineer 2004-2006 Monterey 2004-2007
Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 06-4-2 to update the vehicle model years.
ISSUE This TSB describes the operation and function of the Battery Eye and correct Battery
Recharging procedures.
ACTION Refer to the following Service Tips to avoid misdiagnosis of a battery using the Battery
Eye, and to determine the best way to charge a battery that may be discharged.
SERVICE TIPS
Battery Eye Operation / Function
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Battery Eye Function/Charging/Service > Page 6463
The purpose of the battery eye is to indicate the state of charge of the battery in the assembly plant
and while on the dealership lot. The battery eye can also indicate the state-of-charge when the
vehicle is delivered to the dealership and during the pre-delivery inspection process. The battery
eye is made up of a viewing plate, two balls and a small passage. The balls indicate the specific
gravity of the electrolyte by floating higher or lower in the passageway. It is important to note that
the battery eye checks the specific gravity on only one battery cell.
^ RED usually indicates that the battery state-of-charge is at 40 percent or less
^ YELLOW indicates that the battery state-of-charge is between 40 and 57 percent
^ GREEN indicates that the battery state-of-charge is above 57 percent
^ NO COLOR/BLACK sometimes no color can be seen at all and the eye appears black. This could
happen after the battery has been in service for several years and some of the plate material has
coated the balls
^ CLEAR could happen if the battery case becomes damaged and the electrolyte has fallen below
the plates
The battery eye is a state-of-charge indicator, but should not be used to condemn a battery after
the vehicle has been placed in service. After delivery, many things could happen to cause the
battery eye to lead to misdiagnosis of the battery's actual state-of-charge. After the vehicle has
been in service, the battery eye does not always accurately reflect the battery state-of-charge. The
GR-1 190 Battery Tester/Charge or Micro 490 Digital Battery Analyzer should be used to determine
battery condition.
Do not replace a battery based solely on the indication given by the battery eye. The battery eye
color simply indicates the battery state-of-charge, not its condition. If the eye indicates the battery
may be discharged, Use GR-1 190 Battery Tester/Charger to determine the battery condition or
recharge the battery before testing using the Micro 490.
A red or yellow indicator usually means that the battery is discharged, not defective. Therefore, a
battery with a red or yellow eye should not automatically be replaced. The indicator could remain
red after recharge because the balls are stuck in the passageway.
When new vehicles are delivered to the dealership, be sure to check the state-of-charge indicator
within 72 hours. If the battery eye is red, charge the battery until it is fully charged. Refer to the
following Battery Charging Procedure.
Batteries discharge while the vehicle is on the lot due to normal parasitic key-off loads. Also,
vehicles in inventory are generally driven short distances with heavy electrical loads. Over a period
of time (30 days or more), vehicles still in inventory will have shallow to deeply discharged
batteries. The vehicle's charging system is designed to supply the vehicle's electrical power needs
and maintain the battery near full charge during normal vehicle use. The charging system is not
capable of bringing a deeply discharged battery back near full charge in a short amount of time
such as allowing the vehicle to idle for 15 minutes to "recharge the battery". Discharged batteries
should be charged using an external charger. Refer to the following Battery Charging Procedure.
NOTE
THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS),
EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY
MIXED.
Battery Charging Procedure
Dealers with GR-1 190, use the Diagnostic Fast Charge Mode on GR-1 190 for this procedure and
for dealers without a GR-1 190 the following procedure applies:
The Micro 490 Digital Battery Analyzer (Rotunda Part Number 162-00004) is extremely accurate if
used properly and can distinguish the difference between good, defective, worn out, or
discharged-only batteries. This TSB provides proper battery charging procedures for batteries that
are identified as "discharged-only". Discharged-only batteries can be recharged using the
procedures in this TSB without reducing battery life or charge capacity.
NOTE
BATTERY CHARGERS HAVE IMPROVED GREATLY WITH THE ADDITION OF THE NEW
GENERATION OF "PULSE CHARGERS". THESE NEW CHARGERS PULSE CURRENT INTO
THE BATTERY THAT BREAKS DOWN THE SULFATION LAYER ON THE BATTERY PLATES
AND GENERALLY REDUCE CHARGING TIMES TO LESS THAN 1 HOUR.
^ DEEPLY DISCHARGED - A battery that is drained over a prolonged period of time such as an
unsold vehicle, to the point it is dead
^ SHALLOW DISCHARGE - A battery that is drained by leaving an accessory on for several hours
or a few days, and has a very low charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Battery Eye Function/Charging/Service > Page 6464
The chart information summarizes two (2) recommended methods of charging.
NOTE
COLD BATTERIES WILL NOT READILY ACCEPT A CHARGE. THEREFORE, BATTERIES
SHOULD BE ALLOWED TO WARM TO APPROXIMATELY 41° F (5° C) BEFORE CHARGING.
THIS MAY REQUIRE 4 TO 8 HOURS AT ROOM TEMPERATURE.
A battery which has been completely discharged and left in that condition for a prolonged time
(such as an unsold vehicle) may be slow to accept a charge initially, and in some cases may not
accept a charge at the normal charger setting. When batteries are in this condition, charging can
be started by use of the "dead battery" feature on chargers so equipped. Follow charger
manufacturer's instructions for use of dead battery switch. If switch is the spring-loaded type, it may
need to be held in the ON position for up to 3 minutes.
NOTE
THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS),
EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY
MIXED.
For additional information, refer to the PTS Website, web based Technician training "Fix It Right
The First Time" course "Battery Testing and Charging 34G02W0" (website).
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT070508 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
10655 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical
Specifications
Battery: Electrical Specifications
Amps/Hour Rate/Volts/Cold Cranking Amps
ITEM.....................................................................................................................................................
...................................................SPECIFICATION
Voltage.................................................................................................................................................
..........................................................................12 volt Cold cranking amps........................................
............................................................................................................................................................6
50 CCA Battery amps rating.................................................................................................................
..................................................................................72 amp/hr
Parasitic Draw
Parasitic Draw (Current Drain).............................................................................................................
.................................................Less Than 0.050 amps
NOTE: For testing procedures, please refer to Battery Drain Test.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical
Specifications > Page 6467
Torque Specifications
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 6468
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 6469
Battery: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 6470
Battery: Service Precautions
WARNING:
- When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to
spew through the vent caps resulting in personal injury, damage to the vehicle or to the battery. Lift
with a battery carrier or with your hands on opposite corners.
- Batteries normally produce explosive gases which can cause personal injury. Therefore, do not
allow flames, sparks or lighted substances to come near the battery, always shield your face and
protect your eyes. Always provide ventilation. Failure to follow these instructions may result in
personal injury.
- To avoid accidental deployment and possible injury, the backup power supply must be depleted
before repairing or installing any front or side air bag supplemental restraint system (SRS)
components and before repairing, installing, adjusting or striking components near the front or side
air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood
latches. 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).
Failure to follow these instructions may result in personal injury. Failure to follow these procedures
may result in personal injury.
- When lifting a battery, excessive pressure on the end walls could cause acid to spew through the
vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite
corners. Failure to follow these instructions may result in personal injury.
- Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or
clothing. Also, shield your eyes when working near the battery to protect against possible splashing
of the acid solution. In case of acid contact with the skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician
immediately. Failure to follow these instructions may result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 6471
Battery: Description and Operation
BATTERY
The battery is a 12-volt direct current source connected in a negative ground system. The battery
case is sealed and includes two vent holes to release gases. The battery has three major functions:
- engine cranking power source
- voltage stabilizer for the electrical system
- temporary power when electrical loads exceed the generator output current
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Battery: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step. 4. If the cause is not visually evident, proceed to the pinpoint test. See: Pinpoint Tests
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 6474
Battery: Pinpoint Tests
PINPOINT TEST I: BATTERY CONDITION TEST
Test I1
Normal Operation
Battery condition is determined by measuring battery terminal voltage after a specific discharge
current is applied for a specified time period.
Possible Causes
- battery charge
- battery
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General
Procedures
Battery: Service and Repair General Procedures
BATTERY DISCONNECT
WARNING:
- Batteries normally produce explosive gases which can cause personal injury. Therefore, do not
allow flames, sparks or lighted substances to come near the battery, always shield your face and
protect your eyes. Always provide ventilation. Failure to follow these instructions may result in
personal injury.
- To avoid accidental deployment and possible injury, the backup power supply must be depleted
before repairing or installing any front or side air bag supplemental restraint system (SRS)
components and before repairing, installing, adjusting or striking components near the front or side
air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood
latches. 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).
Failure to follow these instructions may result in personal injury. Failure to follow these procedures
may result in personal injury.
- When lifting a battery, excessive pressure on the end walls could cause acid to spew through the
vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite
corners. Failure to follow these instructions may result in personal injury.
- Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or
clothing. Also, shield your eyes when working near the battery to protect against possible splashing
of the acid solution. In case of acid contact with the skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician
immediately. Failure to follow these instructions may result in personal injury.
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 to relearn its strategy.
Disconnect the battery cables in the order indicated in the illustration and table.
2. To reconnect, reverse the disconnect procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General
Procedures > Page 6477
Battery: Service and Repair Removal and Installation
BATTERY - 4.OL SOHC
WARNING: When lifting a plastic-cased battery, excessive pressure on the end walls could cause
acid to spew through the vent caps resulting in personal injury, damage to the vehicle or to the
battery. Lift with a battery carrier or with your hands on opposite corners.
REMOVAL
1. Disconnect the battery.
2. To remove individual components, only carry out the steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General
Procedures > Page 6478
View 1 Of 2, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General
Procedures > Page 6479
View 1 Of 2, Part 2
3. View 1 of 2. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General
Procedures > Page 6480
View 2 Of 2, Part 1
View 2 Of 2, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General
Procedures > Page 6481
4. View 2 of 2. Remove the components in the order indicated in the illustration and table.
Item 1: Starter Solenoid Terminals Protective Cap Removal Note
1. Raise and support the vehicle.
Item 17: Harness Locator Removal Note
1. Lower the vehicle.
Item 19: Generator B+ Terminal Nut Removal Note
1. Position the generator B+ terminal protective cover aside.
Item 22: Battery Junction Box Nut Removal Note
1. Open the battery junction box cover to access the battery junction box nut.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Page 6482
Micro 490 Digital Battery Analyzer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications
Alternator: Specifications
ITEM.....................................................................................................................................................
...................................................SPECIFICATION
Rating...........................................................................................................75/120 amp (max) @
1800-6000 generator rpm, approx. 500-2000 engine rpm Generator pulley ratio................................
..............................................................................................................................................................
.......2.66:1 Voltage regulator type........................................................................................................
..................................................Electronic internal with generator
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Connector Views
Alternator: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6489
Alternator: Service and Repair
GENERATOR - 4.OL SOHC
REMOVAL
1. Disconnect the battery.
2. Remove the components in the order indicated in the illustration and table.
Item 1: Front End Accessory Drive Belt Tensioner Removal Note
1. Rotate the front end accessory drive belt tensioner counter-clockwise to loosen tension on the
front end accessory drive belt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6490
Item 2: Front End Accessory Drive Belt Removal Note
1. Position the front end accessory drive belt aside.
Item 3: Generator B+ Terminal Nut Removal Note
1. Position the generator B+ terminal protective cover aside.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams
> Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams
> Page 6497
Ignition Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams
> Page 6498
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams
> Page 6499
Ignition Switch: Service and Repair
IGNITION LOCK CYLINDER
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Ignition Lock Cylinder Removal Note
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 6503
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Cable: Customer Interest Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition >
Page 6512
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition
Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition > Page 6518
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Motor: Customer Interest Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition >
Page 6527
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition
Starter Motor: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition > Page 6533
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Page 6534
Starter Motor: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Page 6535
Starter Motor: Service Precautions
WARNING: When carrying out maintenance on the starting system be aware that the heavy gauge
leads are connected directly to the battery. Make sure the protective caps are in place when
maintenance is completed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Page 6536
Starter Motor: Service and Repair
STARTER MOTOR
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 when
maintenance is completed.
REMOVAL
1. Disconnect the battery ground cable. 2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 6540
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 6541
Starter Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 6542
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Console 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Console 1 > Page 6548
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Central Junction Box (CJB)
Electrical Accessory Panel: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Central Junction Box (CJB) > Page 6553
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Central Junction Box (CJB) > Page 6554
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Central Junction Box (CJB) > Page 6555
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Central Junction Box (CJB) > Page 6556
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Central Junction Box (CJB) > Page 6557
Electrical Accessory Panel: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6562
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6563
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6568
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6569
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6570
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6571
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6572
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6573
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6574
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6575
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6576
Fuse: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6577
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6580
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6581
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6582
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6583
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6584
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6585
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6586
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6587
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6588
Fuse: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6589
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6594
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6595
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6596
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6597
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6598
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6599
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6600
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6601
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6602
Fuse Block: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6603
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views
Fuse Block: Connector Views
Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6606
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6607
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6608
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6609
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Connector Views > Page 6610
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6613
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6614
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6615
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6616
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6617
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6618
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6619
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6620
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6621
Fuse Block: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6622
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection > Page 6626
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection > Page 6630
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6635
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6636
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6637
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6638
Multiple Junction Connector: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6639
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6640
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6641
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6642
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6643
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6644
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6645
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6646
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6647
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6648
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6649
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6650
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6651
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6652
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6653
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6654
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6655
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6656
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6657
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6658
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6659
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6660
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6661
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6662
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6663
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6664
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6665
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Joint Connector 1 > Page 6666
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 6671
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 6672
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 6675
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 6676
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 6679
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 6680
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 6681
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 6682
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 6683
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6688
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6692
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge >
Page 6697
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge >
Page 6698
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn >
Page 6701
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn >
Page 6702
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay,
Right Turn
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay,
Right Turn > Page 6705
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay,
Right Turn > Page 6706
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay,
Right Turn > Page 6707
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay,
Right Turn > Page 6708
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay,
Right Turn > Page 6709
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6714
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6715
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6716
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6717
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6718
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6719
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6720
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6721
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6722
Relay Box: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6723
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6726
Relay Box: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6727
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6728
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6729
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6730
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6733
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6734
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6735
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6736
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6737
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6738
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6739
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6740
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6741
Relay Box: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6742
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6747
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6748
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6749
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6750
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6751
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6752
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6753
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6754
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6755
Relay Box: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6756
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6759
Relay Box: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6760
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6761
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6762
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6763
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6766
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6767
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6768
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6769
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6770
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6771
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6772
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6773
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6774
Relay Box: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 6775
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 05-21-7 > Oct > 05 > Audio System - Delayed Power When
Switched ON
Wiring Harness: Customer Interest Audio System - Delayed Power When Switched ON
TSB 05-21-7
10/31/05
DELAYED RADIO POWER UP WHEN THE KEY IS CYCLED ON
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer 4dr and Mountaineer vehicles built after 3/4/2002 equipped with
the 3L2T-18C815-FA CDx6-A Audiophile radio may exhibit a delayed radio power up when the key
is cycled on. The concern may last up to 23 seconds.
ACTION If the concern is verified install a jumper harness and 2004 CD6 Audiophile radio. Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Remove the radio following the Workshop Manual, Section 415.
2. Install the jumper harness between the 14401 dash harness and the new 2004 CD6 Audiophile
radio.
3. Install the radio unit per Workshop Manual, Section 415.
NOTE
WHEN INSTALLING THE RADIO, MAKE SURE ALL EXCESS HARNESS IS FED TO THE
DRIVERS SIDE, BEHIND THE CLUSTER.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052107A 2002-2003 0.3 Hr.
Explorer/Mountaineer: Replace The Radio And Install Jumper Harness (Do Not Use With 18805b,
18805c)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18C815 01
OASIS CODES: 207000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp
ON/DTC B2292 Set
Wiring Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B2292 Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp
ON/DTC B2292 Set > Page 6788
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-21-7 > Oct > 05 > Audio System - Delayed
Power When Switched ON
Wiring Harness: All Technical Service Bulletins Audio System - Delayed Power When Switched ON
TSB 05-21-7
10/31/05
DELAYED RADIO POWER UP WHEN THE KEY IS CYCLED ON
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer 4dr and Mountaineer vehicles built after 3/4/2002 equipped with
the 3L2T-18C815-FA CDx6-A Audiophile radio may exhibit a delayed radio power up when the key
is cycled on. The concern may last up to 23 seconds.
ACTION If the concern is verified install a jumper harness and 2004 CD6 Audiophile radio. Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Remove the radio following the Workshop Manual, Section 415.
2. Install the jumper harness between the 14401 dash harness and the new 2004 CD6 Audiophile
radio.
3. Install the radio unit per Workshop Manual, Section 415.
NOTE
WHEN INSTALLING THE RADIO, MAKE SURE ALL EXCESS HARNESS IS FED TO THE
DRIVERS SIDE, BEHIND THE CLUSTER.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052107A 2002-2003 0.3 Hr.
Explorer/Mountaineer: Replace The Radio And Install Jumper Harness (Do Not Use With 18805b,
18805c)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18C815 01
OASIS CODES: 207000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6798
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6799
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6800
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6801
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6802
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6803
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6804
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6805
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-18-7 > Sep > 05 > Electrical - Wiring
Soldering/Crimping Service Tips > Page 6806
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-3 > Jun > 03 > Restraint System - Air
Bag Lamp ON/DTC B2292 Set
Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC B2292
Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-3 > Jun > 03 > Restraint System - Air
Bag Lamp ON/DTC B2292 Set > Page 6811
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> Recall 03V094000: Running Board Wiring Defect
Auxiliary Step / Running Board: All Technical Service Bulletins Recall 03V094000: Running Board
Wiring Defect
DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running
boards manufactured by Southern Comfort, which include courtesy lights manufactured by
American Technology Components, Inc., might overheat when the wire harness is exposed to
excessive moisture and road salt. This overheating condition can cause the running board to melt
or cause a fire.
REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has
reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-21-7 > Oct > 05 > Audio System - Delayed Power When Switched
ON
Wiring Harness: All Technical Service Bulletins Audio System - Delayed Power When Switched ON
TSB 05-21-7
10/31/05
DELAYED RADIO POWER UP WHEN THE KEY IS CYCLED ON
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer 4dr and Mountaineer vehicles built after 3/4/2002 equipped with
the 3L2T-18C815-FA CDx6-A Audiophile radio may exhibit a delayed radio power up when the key
is cycled on. The concern may last up to 23 seconds.
ACTION If the concern is verified install a jumper harness and 2004 CD6 Audiophile radio. Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Remove the radio following the Workshop Manual, Section 415.
2. Install the jumper harness between the 14401 dash harness and the new 2004 CD6 Audiophile
radio.
3. Install the radio unit per Workshop Manual, Section 415.
NOTE
WHEN INSTALLING THE RADIO, MAKE SURE ALL EXCESS HARNESS IS FED TO THE
DRIVERS SIDE, BEHIND THE CLUSTER.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052107A 2002-2003 0.3 Hr.
Explorer/Mountaineer: Replace The Radio And Install Jumper Harness (Do Not Use With 18805b,
18805c)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18C815 01
OASIS CODES: 207000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6830
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6831
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6832
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6833
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6834
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6835
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6836
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6837
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping Service
Tips > Page 6838
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp ON/DTC
B2292 Set
Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC B2292
Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > NHTSA03V094000 > Mar > 03
> All Technical Service Bulletins for Wiring Harness: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp ON/DTC
B2292 Set > Page 6843
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Console 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Console 1 > Page 6849
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Central Junction Box (CJB)
Electrical Accessory Panel: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Central Junction Box (CJB) > Page 6854
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Central Junction Box (CJB) > Page 6855
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Central Junction Box (CJB) > Page 6856
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Central Junction Box (CJB) > Page 6857
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Central Junction Box (CJB) > Page 6858
Electrical Accessory Panel: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6863
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6864
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6869
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6870
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6871
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6872
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6873
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6874
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6875
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6876
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6877
Fuse: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6878
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6881
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6882
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6883
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6884
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6885
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6886
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6887
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6888
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6889
Fuse: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6890
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6895
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6896
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6897
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6898
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6899
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6900
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6901
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6902
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6903
Fuse Block: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 6904
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views
Fuse Block: Connector Views
Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6907
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6908
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6909
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6910
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector
Views > Page 6911
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6914
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6915
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6916
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6917
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6918
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6919
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6920
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6921
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6922
Fuse Block: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6923
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection > Page 6927
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection > Page 6931
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6936
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6937
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6938
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6939
Multiple Junction Connector: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6940
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6941
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6942
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6943
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6944
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6945
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6946
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6947
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6948
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6949
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6950
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6951
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6952
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6953
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6954
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6955
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6956
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6957
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6958
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6959
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6960
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6961
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6962
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6963
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6964
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6965
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6966
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Joint Connector 1 > Page 6967
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Trailer Tow Relay, Battery Charge > Page 6972
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Trailer Tow Relay, Battery Charge > Page 6973
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams
> Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams
> Trailer Tow Relay, Right Turn > Page 6976
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams
> Trailer Tow Relay, Right Turn > Page 6977
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
and Inspection > Trailer Tow Relay, Right Turn
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
and Inspection > Trailer Tow Relay, Right Turn > Page 6980
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
and Inspection > Trailer Tow Relay, Right Turn > Page 6981
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
and Inspection > Trailer Tow Relay, Right Turn > Page 6982
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
and Inspection > Trailer Tow Relay, Right Turn > Page 6983
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
and Inspection > Trailer Tow Relay, Right Turn > Page 6984
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection > Page 6989
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection > Page 6993
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 6998
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 6999
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 7002
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 7003
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 7006
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 7007
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 7008
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 7009
Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 7010
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7015
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7016
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7017
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7018
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7019
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7020
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7021
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7022
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7023
Relay Box: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7024
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7027
Relay Box: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7028
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7029
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7030
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 7031
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7034
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7035
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7036
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7037
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7038
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7039
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7040
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7041
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7042
Relay Box: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7043
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7048
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7049
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7050
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7051
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7052
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7053
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7054
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7055
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7056
Relay Box: Locations Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 7057
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 7060
Relay Box: Diagrams Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 7061
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 7062
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 7063
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 7064
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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)
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7067
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7068
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7069
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7070
Top Side
Relays
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7071
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7072
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7073
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7074
Fuse
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7075
Relay Box: Application and ID Auxiliary Junction Box (AJB)
Auxiliary Junction Box (AJB) Underhood
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7076
Auxiliary Junction Box (AJB) Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Customer Interest: > 05-21-7 > Oct > 05 > Audio System - Delayed Power When Switched ON
Wiring Harness: Customer Interest Audio System - Delayed Power When Switched ON
TSB 05-21-7
10/31/05
DELAYED RADIO POWER UP WHEN THE KEY IS CYCLED ON
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer 4dr and Mountaineer vehicles built after 3/4/2002 equipped with
the 3L2T-18C815-FA CDx6-A Audiophile radio may exhibit a delayed radio power up when the key
is cycled on. The concern may last up to 23 seconds.
ACTION If the concern is verified install a jumper harness and 2004 CD6 Audiophile radio. Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Remove the radio following the Workshop Manual, Section 415.
2. Install the jumper harness between the 14401 dash harness and the new 2004 CD6 Audiophile
radio.
3. Install the radio unit per Workshop Manual, Section 415.
NOTE
WHEN INSTALLING THE RADIO, MAKE SURE ALL EXCESS HARNESS IS FED TO THE
DRIVERS SIDE, BEHIND THE CLUSTER.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052107A 2002-2003 0.3 Hr.
Explorer/Mountaineer: Replace The Radio And Install Jumper Harness (Do Not Use With 18805b,
18805c)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18C815 01
OASIS CODES: 207000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Customer Interest: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp ON/DTC B2292 Set
Wiring Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B2292 Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Customer Interest: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp ON/DTC B2292 Set > Page 7089
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-21-7 > Oct > 05 > Audio System - Delayed Power When
Switched ON
Wiring Harness: All Technical Service Bulletins Audio System - Delayed Power When Switched ON
TSB 05-21-7
10/31/05
DELAYED RADIO POWER UP WHEN THE KEY IS CYCLED ON
FORD: 2002-2003 Explorer
MERCURY: 2002-2003 Mountaineer
ISSUE Some 2002-2003 Explorer 4dr and Mountaineer vehicles built after 3/4/2002 equipped with
the 3L2T-18C815-FA CDx6-A Audiophile radio may exhibit a delayed radio power up when the key
is cycled on. The concern may last up to 23 seconds.
ACTION If the concern is verified install a jumper harness and 2004 CD6 Audiophile radio. Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Remove the radio following the Workshop Manual, Section 415.
2. Install the jumper harness between the 14401 dash harness and the new 2004 CD6 Audiophile
radio.
3. Install the radio unit per Workshop Manual, Section 415.
NOTE
WHEN INSTALLING THE RADIO, MAKE SURE ALL EXCESS HARNESS IS FED TO THE
DRIVERS SIDE, BEHIND THE CLUSTER.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052107A 2002-2003 0.3 Hr.
Explorer/Mountaineer: Replace The Radio And Install Jumper Harness (Do Not Use With 18805b,
18805c)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18C815 01
OASIS CODES: 207000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7099
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7100
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7101
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7102
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7103
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7104
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7105
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7106
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7107
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp
ON/DTC B2292 Set
Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC B2292
Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-11-3 > Jun > 03 > Restraint System - Air Bag Lamp
ON/DTC B2292 Set > Page 7112
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7118
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7119
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7120
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7121
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7122
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7123
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7124
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7125
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wiring Harness: > 05-18-7 > Sep > 05 > Electrical - Wiring Soldering/Crimping
Service Tips > Page 7126
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications
Alignment: Specifications Alignment Specifications
Front
Caster
LH ........................................................................................................................................................
................................ 5.1 degrees ± 1.0 degrees RH ...........................................................................
............................................................................................................. 5.3 degrees ± 1.0 degrees
Total/Split .............................................................................................................................................
.............................. -0.2 degrees ± 0.4 degrees
Camber
LH ........................................................................................................................................................
.............................. -0.5 degrees ± 0.8 degrees RH ............................................................................
.......................................................................................................... -0.5 degrees ± 0.8 degrees
Total/Split .............................................................................................................................................
.................................. 0 degrees ± 0.8 degrees
Toe (positive value is toe-in, negative value is toe-out)
LH ........................................................................................................................................................
............................ 0.10 degrees ± 0.25 degrees RH ...........................................................................
......................................................................................................... 0.10 degrees ± 0.25 degrees
Total/Split .............................................................................................................................................
.......................... 0.20 degrees ± 0.25 degrees
Rear
Camber
LH ........................................................................................................................................................
.............................. -0.9 degrees ± 0.8 degrees RH ............................................................................
.......................................................................................................... -0.9 degrees ± 0.8 degrees
Total/Split .............................................................................................................................................
................................. 0 degrees ± 0.8 degrees
Toe (positive value is toe-in, negative value is toe-out)
LH ........................................................................................................................................................
............................ 0.10 degrees ± 0.25 degrees RH ...........................................................................
........................................................................................................ 0.10 degrees ± 0.25 degrees
Total/Split .............................................................................................................................................
.......................... 0.20 degrees ± 0.25 degrees
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 7132
Alignment: Specifications General Specifications
Ride Height
Front ....................................................................................................................................................
................. 17 mm (0.68 inch) ± 8 mm (0.32 inch) Rear ......................................................................
............................................................................................... 91 mm (3.64 inch) ± 11 mm (0.44
inch)
Vehicle lean (side-to-side height differences)
Front-maximum ...................................................................................................................................
.................................................. 7 mm (0.28 inch) Rear-maximum .....................................................
................................................................................................................................. 8 mm (0.32 inch)
Wheel Track
Wheel track ..........................................................................................................................................
............................................... 0.6 mm (0.02 inch)
Dogtracking
Dogtracking-maximum (centerline of front tires compared to centerline of rear tires)
........................................................................ 30 mm (1.18 inch)
Ball joint end play
Lower ball joint-maximum vertical
...................................................................................................................................................... 0.8
mm (0.03 inch) Upper ball joint-maximum vertical
...................................................................................................................................................... 0.8
mm (0.03 inch)
Cleaners-Wheel
Custom Bright Metal Cleaner 8A-19522-A
............................................................................................................................................
ESR-M5B194-B
Tire balance weight
Maximum balance weight (total of inner and outer wheel flange); 170 g (6.0 oz.)
Tire Inflation
Tires; See safety certification sticker located on driver door jamb.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 7133
Alignment: Specifications Torque Specifications
Wheel nuts ...........................................................................................................................................
................................................. 135 Nm (100 ft. lbs.) Tire pressure monitoring sensor valve stem
nut ..................................................................................................................................... 7 Nm (62
inch lbs.) Tire pressure monitoring system module screws
.................................................................................................................................... 7 Nm (62 inch
lbs.)
Front Suspension
Wheel hub-to-wheel knuckle bolts
..................................................................................................................................................... 112
Nm (83 ft. lbs.) Tie-rod end nut ............................................................................................................
......................................................................... 70 Nm (52 ft. lbs.) Axle-to-wheel hub nut ..................
.................................................................................................................................................... 250
Nm (184 ft. lbs.) Upper ball joint nut ....................................................................................................
........................................................................... 55 Nm (41 ft. lbs.) Upper arm-to-frame nuts ............
...................................................................................................................................................... 150
Nm (111 ft. lbs.) Lower ball joint nut ....................................................................................................
..................................................................... 175 Nm (129 ft. lbs.) Lower arm-to-frame flag bolt and
nut (forward attachment) ............................................................................................................ 400
Nm (295 ft. lbs.) Lower arm-to-frame nuts (rearward attachment)
.............................................................................................................................. 150 Nm (111 ft.
lbs.) Shock absorber upper mounting plate-to-frame nuts (M8)
................................................................................................................... 30 Nm (22 ft. lbs.) Shock
absorber-to-lower arm bolt and flag nut
................................................................................................................................. 350 Nm (258 ft.
lbs.) Stabilizer bar bracket-to-frame bolts
.................................................................................................................................................... 70
Nm (52 ft. lbs.) Stabilizer bar-to-link nut ..............................................................................................
......................................................................... 70 Nm (52 ft. lbs.) Anti-lock brake sensor bolt ...........
........................................................................................................................................................ 18
Nm (13 ft. lbs.) Caliper anchor plate-to-wheel knuckle bolts
....................................................................................................................................... 112 Nm (83
ft. lbs.) Caliper-to-anchor plate bolts ....................................................................................................
............................................................ 32 Nm (24 ft. lbs.)
Rear Suspension
Upper ball joint-to-wheel knuckle pinch bolt and nut
........................................................................................................................... 90 Nm (66 ft. lbs.)
Upper arm-to-frame bolt and nut
........................................................................................................................................................
133 Nm (98 ft. lbs.) Upper arm-to-frame bolts and flag nuts
................................................................................................................................................ 80 Nm
(59 ft. lbs.) Upper arm bushing-to-upper arm nut
.................................................................................................................................................. 120
Nm (89 ft. lbs.) Lower arm-to-frame flag bolts and nuts
............................................................................................................................................ 175 Nm
(129 ft. lbs.) Lower arm-to-wheel knuckle bolt and nut
........................................................................................................................................ 150 Nm (111
ft. lbs.) Stabilizer bar-to-link nut ...........................................................................................................
............................................................ 25 Nm (18 ft. lbs.) Stabilizer bar bracket-to-frame nuts
...................................................................................................................................................... 55
Nm (41 ft. lbs.) Shock absorber upper mounting plate-to-frame nuts(M8)
.................................................................................................................... 30 Nm (22 ft. lbs.) Shock
absorber-to-lower arm bolt and flag nut
................................................................................................................................. 250 Nm (184 ft.
lbs.) Shock absorber-to-upper mounting plate nut(M12)
.............................................................................................................................. 50 Nm (37 ft. lbs.)
Toe link-to-frame nut ...........................................................................................................................
................................................. 80 Nm (59 ft. lbs.) Toe link-to-wheel knuckle pinch bolt and nut
...................................................................................................................................... 90 Nm (66 ft.
lbs.) Toe link adjustment locknut .........................................................................................................
........................................................ 70 Nm (52 ft. lbs.) Parking brake cable bracket-to-lower arm
bolt ....................................................................................................................................... 12 Nm (9
ft. lbs.) Axle-to-wheel hub retainer nut
.........................................................................................................................................................
275 Nm (203 ft. lbs.) Rear caliper bolts ...............................................................................................
................................................................................... 32 Nm (24 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7134
Alignment: Description and Operation
Suspension System
The front caster and camber are adjusted by means of removing set shims at the upper control
arm-to-frame mounting bolts and installing washers (W-705040-S426) to allow the arm to be
adjusted in the frame slots. A caster split adjustment can be made by turning an adjustment bolt
located on the RH lower arm rearward frame mountings. Front toe is adjusted by the use of the
front wheel spindle tie-rod. The rear camber is adjusted by removing the set shim from the
rearward lower control arm to frame mounting bolt and installing a washer (W-705040-S426) to
allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe
link.
Camber
Part 2 Of 3
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7135
the vehicle the best directional stability characteristics when loaded and driven. The caster setting
is not related to tire wear.
Toe
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.
Ride Height
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7136
Front Ride Height Measurement
Rear Ride Height Measurement
Wheel Track
Wheel Track
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7137
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.
Wander Wander is the tendency of the vehicle to require frequent, random left and right steering
wheel corrections to maintain a straight path down a level road.
Shimmy Shimmy, as observed by the driver, is large consistent, rotational oscillations of the
steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually
experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes
or irregularities in the road surface.
Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with
various road surfaces and observed by the driver as small rotational oscillations of the steering
wheel.
Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor
return of the steering wheel to center after a turn or the steering correction is completed.
Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be
overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does
with hands off the steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment
Alignment: Service and Repair Camber and Caster Adjustment
Wheel Alignment
Front Camber and Caster Adjustment
1. NOTE: The upper arm-to-frame mounting bolts have set shims that must be replaced with
washers (W-705040-S426) to allow for adjustment of
the arm in the frame slot. The vehicle should be supported by the lower arm to ease movement of
the upper arm in the slot.
Remove the nuts and the shims. ^
Discard the nuts and shims.
^ Install new washers (W-705040-S426) and nuts and snug the nuts.
2. To adjust the caster and camber, refer to the chart.
^ Make adjustments that require moving the front and the rear of the upper arm equally.
3. Tighten the nuts.
4. NOTE: A caster split adjustment can be made by turning an adjustment bolt located on the RF
lower arm rearward frame mounting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7140
Loosen the nuts and adjust the bolt clockwise to decrease the RH caster or counterclockwise to
increase the RH caster.
5. Check and, if necessary, adjust the front toe.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7141
Alignment: Service and Repair Rear Camber Adjustment
Rear Camber Adjustment
1. NOTE: The lower arm rearward mounting bolt has a set shim that must be removed and
replaced with a washer (W-705040-S426) to allow for
the adjustment of the arm in the frame slot.
Remove the nut and the set shim. ^
Discard the nut and set shim. Install the washer (W-705040-S426) and the nut and snug the nut.
2. NOTE: A prybar may be used between the lower arm and the frame pocket to aid in moving the
arm outward.
To decrease the camber, move the lower arm outward.
3. NOTE: Adjustable pliers may be used to aid in moving the arm inward.
To increase the camber, move the lower arm inward.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7142
4. Tighten the nut. 5. Check and, if necessary, adjust the rear toe.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7143
Alignment: Service and Repair Toe Adjustment
Front
Front Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight ahead" position using a suitable holding device.
3. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is
rotated.
Remove the clamps.
4. Loosen the nuts.
^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads.
5. Rotate the front wheel spindle tie-rods. 6. Start the engine and recenter the steering wheel.
^ Recheck the toe settings and adjust if necessary.
7. CAUTION: Make sure to hold the tie-rod end stationary with a wrench while tightening the nut or
damage to the boot can occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7144
Tighten the nuts.
8. Install the clamps.
Rear
Rear Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight ahead" position using a suitable holding device.
3. Loosen the nuts.
^ Clean and lubricate the nut(s) and rear toe link threads.
4. While holding the toe link spindle tie-rod, rotate the toe link adjuster.
5. NOTE: Make sure the toe settings are not disturbed while tightening the nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 7145
While holding the adjuster, tighten the nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations
View 151-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 7151
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 7152
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7158
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7163
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications > Page 7168
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications > Page 7169
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Specifications > Page 7170
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7175
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7176
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7177
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7178
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7179
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Power Steering System Purging
Special Tools
Special Tool(s)
CAUTION: If the air is not purged from the power steering system correctly, premature power
steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of
aerated fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The
power steering purge procedure must be carried out
prior to any component repair for which power steering noise complaints are accompanied by
evidence of aerated fluid.
Remove the reservoir cap. Check the fluid.
2. Raise the front wheels off the floor.
3. Tightly insert the stopper of the vacuum pump into the reservoir.
4. Apply and maintain maximum vacuum. 5. Cycle the steering wheel fully to the left and right 10
times. 6. Release the vacuum and remove the vacuum pump.
7. CAUTION: Do not overfill the power steering pump reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 7184
Fill the reservoir.
8. Start the engine.
9. Reinstall the vacuum pump. Apply and maintain maximum vacuum.
10. 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
can occur.
Cycle the steering wheel fully to the left and right 10 times.
11. Stop the engine, release the vacuum, and remove the vacuum pump. 12. Lower the vehicle.
13. Install the reservoir cap 14. Check for fluid leaks at all of the connections. If the power steering
fluid shows signs of air, repeat this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7189
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications
Fill between the MIN and MAX lines on the reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications > Page 7192
Power Steering Fluid: Fluid Type Specifications
Lubricant ..............................................................................................................................
Motorcraft MERCON (R) Multi-Purpose Transmission Fluid
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Specifications
Power Steering Fluid Cooler: Specifications
Fluid cooler bolts .................................................................................................................................
....................................................... 11 Nm (8 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Specifications
Power Steering Fluid Reservoir: Specifications
Pump/fluid reservoir bracket nut (4.6L)
................................................................................................................................................... 25
Nm (18 ft. lbs.) Fluid reservoir bracket bolts (4.0L)
.............................................................................................................................................................
11 Nm 8 ft. lbs.) Fluid reservoir bolts ...................................................................................................
............................................................................. 7 Nm (62 inch lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure line fitting-to-pump ................................................................................................................
.................................................... 65 Nm (48 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications
Power Steering Pump: Specifications
Power Steering Pump
Flow rate @ 74 degrees-80 degrees C (165 degrees-175 degrees F) and engine speed set at
2,100 rpm and power steering analyzer set at 345 kPa (50 psi)
..............................................................................................................................................................
................ 7.6-9.1 liters/minute (2.0-2.4 gpm)
Flow rate-minimum @ 74 degrees-80 degrees C (165 degrees-175 degrees F), power steering
analyzer set at 5,102 kPa (750 psi) and engine speed set at idle
..............................................................................................................................................................
......................... 4.35 liters/minute (1.15 gpn)
Maximum pressure @ 74 degrees-80 degrees C (165 degrees-175 degrees F) and engine speed
set at 2,100 rpm
..............................................................................................................................................................
........................................ 1,034 kPa (150 psi)
Relief pressure ....................................................................................................................................
........................................... 1200-1380 @ 500 rpm
Pump bolts (4.6L) ................................................................................................................................
..................................................... 20 Nm (15 ft. lbs.) Pump bolts (4.0L) .............................................
........................................................................................................................................ 25 Nm (18 ft.
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 7205
Power Steering Pump: Application and ID
Pump Identification
CAUTION: Always use the ID code when ordering service parts.
The pump identification code is located on a tag attached to the power steering pump.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 7206
Power Steering Pump: Service and Repair
Power Steering Pump-4.0L SOHC
Special Tools
Special Tool(s)
1. With the vehicle in NEUTRAL, position the vehicle on a hoist.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 7207
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 7208
2. Remove the components in the order indicated in the following illustration and table. 3. To install,
reverse the removal procedure. 4. Fill, purge and leak test the system.
Item 15: Pulley Bolts Removal Note 1. Loosen the bolts, position the drive belt aside, and then
remove the bolts.
Item l9: O-Ring Installation Note
1. Using the special tool, install a new O-ring on the pressure line fitting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 7213
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 7217
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions > Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions > Technician Safety Information > Page 7223
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7226
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7227
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7228
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7229
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7230
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7231
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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System Information > Service and Repair > Air Bag Disarming and Arming > Page 7232
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7233
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7234
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7235
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7236
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7237
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7238
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7239
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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
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10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7241
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7242
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7243
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7244
- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7245
10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7246
12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7247
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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System Information > Service and Repair > Air Bag Disarming and Arming > Page 7248
Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7249
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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7250
3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7251
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7252
11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7253
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7254
All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7255
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7256
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7257
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7258
13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7259
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7260
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7261
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7262
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Page 7263
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
Steering Gear: Specifications
Power Steering Gear
Turning effort .......................................................................................................................................
..................................................... 4.5 kg (10 lbs.) Tie-rod articulation torque .....................................
............................................................................................................................................... 1-3 Nm
Turns lock-to-lock ................................................................................................................................
....................................................................... 3.70
Steering gear-to-bracket stud bolts and nuts
......................................................................................................................................... 200 Nm
(148 ft. lbs.) Steering gear bracket-to-crossmember bolts
............................................................................................................................................. 70 Nm
(52 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7267
Steering Gear: Application and ID
Steering Gear Identification
The steering gear is identified by the color of the valve tower cover seal. The 4.0L seal is gray and
the 4.6L seal is red.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7268
Steering Gear: Service and Repair
Steering Gear
Special Tool(s)
Special Tool(s)
1. With the vehicle in NEUTRAL, position the vehicle on a hoist.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7269
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7270
2. Remove the components in the order indicated in the following illustration and table.
3. To install, reverse the removal procedure. 4. Fill, purge and leak test the system. 5. Check and, if
necessary, align the front end.
Item 6: Intermediate Shaft Removal Note 1. Do not allow the steering column shaft to rotate while
the intermediate shaft is disconnected or damage to the clockspring can result. If there is
evidence that the shaft has rotated, the clockspring must be removed and recentered.
Item 13: Outer Tie-Rod Removal Note
1. Using the special tool, separate the tie-rod end from the wheel knuckle.
^ For reference during installation, count the turns required to remove the tie-rod.
Item 18: Steering Gear Removal Note
NOTE: On 4x4 vehicles, the following steps (LH lower arm only) must be carried out to provide
clearance to remove the steering gear.
1. CAUTION: Do not tighten the LH lower arm inboard mounting nuts until the installation
procedure is complete and the weight of the vehicle is
resting on the wheel and tire assemblies. Make sure to tighten the forward flag bolt and nut before
tightening the rearward nuts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7271
Remove the nut and bolt. ^
Discard the nut.
2. Remove and discard the nuts.
3. Remove the bolt and flag nut.
^ Discard the flag nut.
4. Remove the nut and stabilizer bar link.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 7272
5. Remove the steering gear.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7281
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7287
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7288
Steering Wheel: Specifications
Steering wheel bolt ..............................................................................................................................
..................................................... 40 Nm (30 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 7289
Steering Wheel: Service and Repair
STEERING WHEEL AUDIO CONTROLS
REMOVAL
1. Remove the driver airbag module.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
Front Suspension
Tie-rod end nut ....................................................................................................................................
................................................. 70 Nm (52 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7299
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 7300
Ball Joint: Specifications General Specifications
Front Suspension
Upper ball joint nut ...............................................................................................................................
................................................ 55 Nm (41 ft. lbs.) Lower ball joint nut ................................................
.......................................................................................................................... 175 Nm (129 ft. lbs.)
Rear Suspension
Upper ball joint-to-wheel knuckle pinch bolt and nut
........................................................................................................................... 90 Nm (66 ft. lbs.)
Ball joint end play
Lower ball joint-maximum vertical
.................................................................................................................................................... 0.8
mm (0.032 inch) Upper ball joint-maximum vertical
.................................................................................................................................................... 0.2
mm (0.008 inch)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection
Ball Joint: Testing and Inspection Ball Joint Inspection
Ball Joint Inspection
1. Raise and support the vehicle. 2. Prior to carrying out 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 pries upward on the bottom of the tire, observe the relative movement
between the spindle and the lower arm ball joint. Any
movement at or exceeding the specification indicates a worn or damaged lower ball joint. Install a
new lower arm as necessary.
5. While an assistant pries upward on the bottom of the tire, observe the relative movement
between the spindle and the upper arm ball joint.
Movement at or exceeding the specification indicates a worn or damaged upper ball joint. Install a
new upper arm as necessary.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 7303
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Ball Joint Inspection > Page 7304
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7305
Ball Joint: Service and Repair
Ball Joint-Lower, 4WD
Special Tool(s)
Special Tool(s)
Material
Material
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove and discard the nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7306
3. NOTE: The wheel speed sensor connectors are located in the engine compartment and are
secured to the fender aprons.
Disconnect the wheel speed sensor connector.
4. Remove the wheel and tire assembly.
5. Detach the harness from the retainers.
6. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide
a suitable support.
Remove the bolts and position the brake caliper and support bracket aside.
7. Remove the brake disc.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7307
8. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose in the hub.
9. Remove and discard the cotter pin and the castellated nut.
10. 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.
Using the special tool, separate the tie-rod from the wheel knuckle.
11. Remove and discard the cotter pin and the castellated nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7308
12. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle will result.
Using the special tool, separate the lower ball joint from the wheel knuckle. Reinstall and
hand-tighten the lower ball joint castellated nut.
13. Remove and discard the upper ball joint nut.
14. CAUTION: Secure the front axle shaft to prevent the CV joint and boots from overextending.
Failure to do so can cause damage to the CV joint
and boots.
CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the
wheel knuckle will result.
CAUTION: Do not damage the ball joint when installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
15. Remove the hand-tightened lower ball joint castellated nut and remove the wheel knuckle.
16. Remove the snap ring from the ball joint. Discard the snap ring.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 7309
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: Apply a thin coat of silicone sealant to the wheel hub mounting surfaces before installation.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information >
Specifications
Control Arm: Specifications
Front Suspension
Upper arm-to-frame nuts .....................................................................................................................
............................................. 150 Nm (111 ft. lbs.) Lower arm-to-frame flag bolt and nut (forward
attachment) ............................................................................................................ 400 Nm (295 ft.
lbs.) Lower arm-to-frame nuts (rearward attachment)
.............................................................................................................................. 150 Nm (111 ft.
lbs.)
Rear Suspension
Upper arm-to-frame bolt and nut
........................................................................................................................................................
133 Nm (98 ft. lbs.) Upper arm-to-frame bolts and flag nuts
................................................................................................................................................ 80 Nm
(59 ft. lbs.) Upper arm bushing-to-upper arm nut
.................................................................................................................................................. 120
Nm (89 ft. lbs.) Lower arm-to-frame flag bolts and nuts
............................................................................................................................................ 175 Nm
(129 ft. lbs.) Lower arm-to-wheel knuckle bolt and nut
........................................................................................................................................ 150 Nm (111
ft. lbs.)
Lower arm-to-frame nuts .....................................................................................................................
................................................. 150 Nm (111 ft. lbs.) Lower arm-to-crossmember flag bolt and nut
....................................................................................................................................... 400 Nm (295
ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front
Control Arm: Service and Repair Front
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Front
Special Tool(s)
1. On 4x4 vehicles, loosen the axle retainer nut
2. NOTE: The wheel speed sensor electrical connectors are located in the engine compartment
secured to the fender aprons
Disconnect the wheel speed sensor.
3. Remove the wheel and tire assembly.
4. To remove individual suspension components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7315
5. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7316
6. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and
table. 7. To install, reverse the removal procedure.
Item 1: Axle-to-Wheel Hub Nut Removal Note
1. Remove the nut and, using the special tool, separate the outboard CV joint from the wheel hub.
Item 2: Speed Sensor Harness Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7317
1. Detach the wheel speed sensor harness from the brake hose
Item 5: Brake Caliper, Pads and Anchor Plate Removal Note
1. CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose can
occur.
Position the caliper, pads and anchor plate aside
Item 10: Tie-Rod End-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod from the wheel knuckle
Item 11: Lower Ball Joint-to-Wheel knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle
Item 12: Upper Ball Joint-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7318
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
Item 27: Lower Arm Installation Note 1. Check and, if necessary, align the front end.
Item 24: Lower Arm-to-Frame Nut (forward mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 21: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Item 16: Upper Arm Installation Note 1. Check and, if necessary, align the front end.
Item 13: Wheel Knuckle Installation Note 1. Check and, if necessary, align the front end.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7319
Control Arm: Service and Repair Rear
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7320
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7321
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7322
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7323
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7324
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Material
Material
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7332
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7333
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7334
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7335
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7336
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 7341
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Specifications
Stabilizer Link: Specifications
Front Suspension
Stabilizer bar-to-link nut .......................................................................................................................
................................................ 70 Nm (52 ft. lbs.)
Rear Suspension Stabilizer bar-to-link nut ..........................................................................................
................................................................................. 25 Nm (18 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front
Stabilizer Link: Service and Repair Front
Stabilizer Bar and Link-Front
1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7348
Stabilizer Link: Service and Repair Rear
Stabilizer Bar and Link - Rear
1. Remove the wheel and tire assemblies. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 7: Stabilizer Bar Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the knuckle.
Remove the nut and detach the RH upper ball joint.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7349
2. CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose can
occur.
Remove the bolts and position the brake caliper aside.
3. Unclip the vapor line from the fuel tank.
4. From the RH side of the vehicle, remove the stabilizer bar.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front
Suspension Spring ( Coil / Leaf ): Service and Repair Front
Shock Absorber and Spring Assembly-Front
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 5: Shock Absorber and Spring Assembly Removal Note 1. For additional information on the
disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber
and Spring
Assembly.
Item 3: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Front > Page 7354
Suspension Spring ( Coil / Leaf ): Service and Repair Rear
Shock Absorber and Spring Assembly-Rear
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 8: Shock Absorber and Spring Assembly Removal Note 1. For additional information on the
disassembly and assembly refer to Shock Absorber and Spring Assembly.
Item 6: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications
Suspension Strut / Shock Absorber: Specifications
Front Suspension
Shock absorber upper mounting plate-to-frame nuts (M8)
................................................................................................................... 30 Nm (22 ft. lbs.) Shock
absorber-to-lower arm bolt and flag nut
................................................................................................................................. 350 Nm (258 ft.
lbs.) Shock absorber-to-upper mounting plate nut (M12)
............................................................................................................................. 56 Nm (41 ft. lbs.)
Rear Suspension
Shock absorber upper mounting plate-to-frame nuts(M8)
.................................................................................................................... 30 Nm (22 ft. lbs.) Shock
absorber-to-lower arm bolt and flag nut
................................................................................................................................. 250 Nm (184 ft.
lbs.) Shock absorber-to-upper mounting plate nut(M12)
.............................................................................................................................. 50 Nm (37 ft. lbs.)
Shock absorber-to-lower arm bolt and flag nut
..................................................................................................................................... 350 Nm (258
ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Installation
Suspension Strut / Shock Absorber: Service and Repair Removal and Installation
Front
Shock Absorber and Spring Assembly-Front
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure.
Item 5: Shock Absorber and Spring Assembly Removal Note 1. For additional information on the
disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber
and Spring
Assembly.
Item 3: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Rear
Shock Absorber and Spring Assembly-Rear
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Installation > Page 7360
3. To install, reverse the removal procedure.
Item 8: Shock Absorber and Spring Assembly Removal Note 1. For additional information on the
disassembly and assembly refer to Shock Absorber and Spring Assembly.
Item 6: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Installation > Page 7361
Suspension Strut / Shock Absorber: Service and Repair Disassembly and Assembly
Shock Absorber and Spring Assembly
1. Remove the shock absorber and spring assembly.
2. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber. 3. Disassemble the components in the order indicated in the following illustration
and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Installation > Page 7362
4. To assemble, reverse the disassembly procedure.
Item 1: Shock Absorber-to-Upper Mount Nut Disassembly Note
1. While holding the flats of the washer, remove the nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
Wheel Bearing: Customer Interest Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
> Page 7371
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
> Page 7372
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub Bearing Noise
> Page 7373
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise
Wheel Bearing: All Technical Service Bulletins Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 7379
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 7380
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 7381
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 7382
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tires are off of the ground.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the wheel and tire assembly.
Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire from the front wheel bearings. If movement exists, a new bearing must be
installed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Front
Special Tool(s)
1. On 4x4 vehicles, loosen the axle retainer nut
2. NOTE: The wheel speed sensor electrical connectors are located in the engine compartment
secured to the fender aprons
Disconnect the wheel speed sensor.
3. Remove the wheel and tire assembly.
4. To remove individual suspension components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7385
5. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7386
6. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and
table. 7. To install, reverse the removal procedure.
Item 1: Axle-to-Wheel Hub Nut Removal Note
1. Remove the nut and, using the special tool, separate the outboard CV joint from the wheel hub.
Item 2: Speed Sensor Harness Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7387
1. Detach the wheel speed sensor harness from the brake hose
Item 5: Brake Caliper, Pads and Anchor Plate Removal Note
1. CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose can
occur.
Position the caliper, pads and anchor plate aside
Item 10: Tie-Rod End-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod from the wheel knuckle
Item 11: Lower Ball Joint-to-Wheel knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle
Item 12: Upper Ball Joint-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7388
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
Item 27: Lower Arm Installation Note 1. Check and, if necessary, align the front end.
Item 24: Lower Arm-to-Frame Nut (forward mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 21: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Item 16: Upper Arm Installation Note 1. Check and, if necessary, align the front end.
Item 13: Wheel Knuckle Installation Note 1. Check and, if necessary, align the front end.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7389
Wheel Bearing: Service and Repair Rear
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7390
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7391
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7392
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7393
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7394
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front Suspension
Axle-to-wheel hub nut ..........................................................................................................................
............................................. 250Nm (184 ft. lbs.)
Rear Suspension
Axle-to-wheel hub retainer nut
.........................................................................................................................................................
275 Nm (203 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the
vehicle to move.
- Make sure to properly locate jack stands under the frame to prevent the vehicle from falling.
CAUTION: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack.
- Position the jack to avoid contact with the fuel tank.
Jacking Points
Jacking Points
1. The front jacking points are indicated by a cut-out in the frame, located behind the front tire and
wheel.
2. 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.
The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel.
LIFTING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 7403
Lifting Points
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
- Position the hoist adapters to avoid contact with the fuel tank.
The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
lifting equipment before use.
Position the hoist directly under the frame rails.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Module > Component Information > Locations
View 151-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Module > Component Information > Locations > Page 7408
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Module > Component Information > Locations > Page 7409
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Specifications > Page 7414
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Specifications > Page 7415
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Specifications > Page 7416
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions
Low Tire Pressure Indicator: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7422
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7423
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7424
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7425
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7426
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7427
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7428
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7429
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7430
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7431
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7432
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7433
Low Tire Pressure Indicator: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7434
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7435
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7436
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7437
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7438
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7439
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7440
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 7441
Low Tire Pressure Indicator: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
118-1
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module
> Component Information > Locations
View 151-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module
> Component Information > Locations > Page 7445
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module
> Component Information > Locations > Page 7446
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Specifications > Page 7450
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Specifications > Page 7451
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Specifications > Page 7452
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7461
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7462
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7463
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7469
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7470
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7471
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise
Wheel Bearing: Customer Interest Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 7480
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 7481
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear Axle Hub
Bearing Noise > Page 7482
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise
Wheel Bearing: All Technical Service Bulletins Drivetrain - Rear Axle Hub Bearing Noise
TSB 05-25-8
12/26/05
NOISE FROM REAR WHEEL HUB BEARINGS
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
This article supersedes TSB 05-17-10 to update the Service Procedure.
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
noise from the rear wheel hub bearings. Previous service procedures required service replacement
of the wheel hub bearing assembly, base part (1109). This new service procedure allows
replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise
condition.
ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following
Service Procedure.
SERVICE PROCEDURE
CAUTION
SUSPENSION FASTENERS ARE CRITICAL.
WHEN REPLACING SUSPENSION FASTENERS USE ORIGINAL EQUIPMENT FASTENERS,
OR FASTENERS OF EQUIVALENT QUALITY AND DESIGN. DO NOT INSTALL A
REPLACEMENT FASTENER OF LESSER QUALITY OR DIFFERENT DESIGN. PROPER
TORQUE VALUES MUST BE OBSERVED DURING REASSEMBLY TO ENSURE CORRECT
RETENTION OF ALL COMPONENTS. MAKE SURE THE FASTENERS ARE REINSTALLED IN
THE SAME ORIENTATION AS WHEN REMOVED.
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.
NOTE
HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING.
1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1).
Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N.m).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise > Page 7488
2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in
(8 N.m).
3. Remove the parking brake shoes. For additional information, refer to Workshop Manual, Section
206-05.
4. Remove and discard the toe link-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE TOE LINK FROM THE WHEEL
KNUCKLE.
5. Remove the bolt and separate the toe link from the wheel knuckle.
6. Remove and discard the upper arm-to-wheel knuckle nut. To install, tighten to 66 lb-ft (90 N.m).
CAUTION
DO NOT DAMAGE THE BOOT WHILE SEPARATING THE BALL JOINT FROM THE WHEEL
KNUCKLE.
7. Remove the bolt and separate the upper arm from the wheel knuckle.
8. Using the Special Tool 205-D070 (D93P-1175-B), or equivalent, press the outboard CV joint until
it is loose from the hub (Figure 3).
9. Remove and discard the lower arm-to-wheel knuckle nut. To install, tighten to 111 lb-ft (150
N.m).
10. Remove the lower arm-to-wheel knuckle bolt.
11. Remove the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise > Page 7489
12. Remove the three (3) brake disc shield-to-wheel knuckle bolts (Figure 4). To install, tighten to
10 lb-ft (13 N.m)
13. Using a suitable press, remove the wheel hub (Figure 5).
14. Remove the brake disc shield.
NOTE
THIS STEP MAY NOT BE NECESSARY IF THE INNER WHEEL BEARING RACE REMAINS IN
THE WHEEL KNUCKLE AFTER REMOVING THE WHEEL HUB.
15. Using Special Tool 205-D002, or equivalent, press the inner wheel bearing race from the wheel
hub (Figure 6).
16. Remove the wheel bearing retainer ring.
17. Using a suitable press, remove and discard the wheel bearing.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > 05-25-8 > Dec > 05 > Drivetrain - Rear
Axle Hub Bearing Noise > Page 7490
18. To install, reverse the removal procedure.
NOTE
DURING REASSEMBLY ALWAYS INSTALL NEW:
^ AXLE-TO-WHEEL HUB RETAINER NUT
^ TOE LINK-TO-WHEEL KNUCKLE NUT
^ UPPER ARM-TO-WHEEL KNUCKLE NUT
^ LOWER ARM-TO-WHEEL KNUCKLE NUT
^ WHEEL BEARING
REFER TO PART CATALOG FOR CORRECT APPLICATION AND PART NUMBER.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052508A 2002-2005 1.5 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace One Rear Wheel Bearing (Do Not Use With
1225A, 1225AT)
052508B 2002-2005 2.7 Hrs.
Explorer/Mountaineer 2003-2005 Aviator: Replace Both Rear Wheel Bearings (Do Not Use With
1225A, 1225AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1215 30
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 7491
Wheel Bearing: Testing and Inspection
Wheel Bearing Inspection
1. Raise the vehicle until the tires are off of the ground.
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the wheel and tire assembly.
Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire from the front wheel bearings. If movement exists, a new bearing must be
installed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Front
Special Tool(s)
1. On 4x4 vehicles, loosen the axle retainer nut
2. NOTE: The wheel speed sensor electrical connectors are located in the engine compartment
secured to the fender aprons
Disconnect the wheel speed sensor.
3. Remove the wheel and tire assembly.
4. To remove individual suspension components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7494
5. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7495
6. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and
table. 7. To install, reverse the removal procedure.
Item 1: Axle-to-Wheel Hub Nut Removal Note
1. Remove the nut and, using the special tool, separate the outboard CV joint from the wheel hub.
Item 2: Speed Sensor Harness Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7496
1. Detach the wheel speed sensor harness from the brake hose
Item 5: Brake Caliper, Pads and Anchor Plate Removal Note
1. CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose can
occur.
Position the caliper, pads and anchor plate aside
Item 10: Tie-Rod End-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod from the wheel knuckle
Item 11: Lower Ball Joint-to-Wheel knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle
Item 12: Upper Ball Joint-to-Wheel Knuckle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7497
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
Item 27: Lower Arm Installation Note 1. Check and, if necessary, align the front end.
Item 24: Lower Arm-to-Frame Nut (forward mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 21: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Item 16: Upper Arm Installation Note 1. Check and, if necessary, align the front end.
Item 13: Wheel Knuckle Installation Note 1. Check and, if necessary, align the front end.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7498
Wheel Bearing: Service and Repair Rear
Wheel Bearing, Hub, Knuckle, Upper Arm and Lower Arm-Rear
Special Tool(s)
1. Remove the parking brake shoes.
2. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7499
3. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7500
4. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and
table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7501
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7502
5. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and
table. 6. To install, reverse the removal procedure. 7. Check and, if necessary, align the rear end.
Item 1: Axle Nut Removal Note
1. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components can
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
Item 3: Toe Link-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the toe link from the wheel knuckle.
Remove the bolt and separate the toe link from the wheel knuckle.
Item 5: Upper Arm-to-Wheel Knuckle Bolt Removal Note
1. CAUTION: Do not damage the boot while separating the ball joint from the wheel knuckle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7503
Remove the bolt and separate the upper arm from the wheel knuckle
Item 10: Wheel Hub Removal Note
1. Using a suitable press, remove the wheel hub.
Item 13: Wheel Bearing Removal Note 1. Using a suitable press, remove the wheel bearing.
Item 17: Stabilizer Bar Link-to-Stabilizer Bar Nut and Bushing Removal Note 1. Remove the nut
and the stabilizer bar link.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Removal Note 1. Remove the spare tire to
gain access to the bolts.
Item 30: Upper Arm-to-Frame Bolt (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 26: Upper Arm-to-Frame Bolt (Rearward Mounting) Installation Note
1. CAUTION: Make sure that the upper arm-to-frame mounting bolts are routed through the frame
and the bushing before tightening.
Do not tighten until the installation procedure is complete and the weight of the vehicle is resting on
the wheel and tire assemblies.
Item 23: Lower Arm-to-Frame Nut (Forward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and tire
assemblies.
Item 20: Lower Arm-to-Frame Nut (Rearward Mounting) Installation Note 1. Do not tighten until the
installation procedure is complete and the weight of the vehicle is resting on the wheel and the
assemblies.
Item 18: Shock Absorber-to-Lower Arm Bolt Installation Note 1. Do not tighten until the installation
procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Front Suspension
Axle-to-wheel hub nut ..........................................................................................................................
............................................. 250Nm (184 ft. lbs.)
Rear Suspension
Axle-to-wheel hub retainer nut
.........................................................................................................................................................
275 Nm (203 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel nuts ...........................................................................................................................................
.................................................. 135Nm (100 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Operation
Accumulator HVAC: Description and Operation
SUCTION ACCUMULATOR
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The suction accumulator is mounted to the right of the radiator support. The evaporator outlet line
attaches directly to the inlet of the suction accumulator and the compressor manifold and tube
assembly attaches to the suction accumulator outlet.
After entering the inlet of the suction accumulator, 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 inlet 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Operation > Page 7515
Accumulator HVAC: Service and Repair
SUCTION ACCUMULATOR
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Recover the refrigerant. 2. Remove the air cleaner. 3. Remove the radiator grille.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator
View 151-11
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator > Page 7521
View 151-32
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator > Page 7522
View 151-11
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Temperature Blend Door Actuator, Driver
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Temperature Blend Door Actuator, Driver > Page 7525
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Temperature Blend Door Actuator, Driver > Page 7526
Air Door Actuator / Motor: Diagrams Temperature Blend Door Actuator
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Temperature Blend Door Actuator, Driver > Page 7527
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Page 7528
Air Door Actuator / Motor: Service Precautions
CAUTION:
- To avoid damaging the sunload sensor electrical connector, remove the grille just enough to
access the connector.
- Be sure the instrument panel is properly supported to avoid possible damage to the instrument
panel wiring and components.
- To avoid damage to the instrument panel wiring or components, do not use excessive force when
moving the instrument panel away from the dash panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Description and Operation > Manual Climate Control
Air Door Actuator / Motor: Description and Operation Manual Climate Control
TEMPERATURE BLEND DOOR ACTUATOR
The temperature blend door actuator: is located on the heater core and evaporator core housing.
- moves the temperature blend door on command of the temperature control switch.
- contains a reversible electric motor.
VACUUM CONTROL MOTORS
The four vacuum control motors: direct system airflow to the vehicle interior as determined by the function selector switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Description and Operation > Manual Climate Control > Page 7531
Air Door Actuator / Motor: Description and Operation Dual Automatic Temperature Control
TEMPERATURE BLEND DOOR ACTUATORS
The DATC system utilizes two temperature blend door actuators to control two separate
temperature blend doors that independently vary the LH side and RH side temperature settings, as
desired. The temperature blend door actuators: are located on the heater core and evaporator core housing.
- moves the temperature blend door on command from the DATC module.
- 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 temperature
blend door.
- apply a 5 volt signal to one end of the potentiometers and ground to the other. The voltage
available at the wiper indicates the position of each potentiometer. The expressed value of the
actuator wiper voltage is sent to the DATC module and is matched with an expected wiper voltage
value. The DATC module then drives the actuator motor in whichever direction is necessary to
make the actuator wiper voltage agree with the expected DATC module wiper voltage value.
VACUUM CONTROL MOTORS
The four vacuum control motors: are actuated by the ATC solenoid and manifold based on input from the DATC module.
- position the plenum doors to direct system airflow to the vehicle interior as determined by the
DATC module settings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control
Air Door Actuator / Motor: Service and Repair Main Climate Control
LH
TEMPERATURE BLEND DOOR ACTUATOR - LH
REMOVAL
1. Remove the floor console. 2. Remove the steering column opening cover.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
RH, DATC
TEMPERATURE BLEND DOOR ACTUATOR - RH, DATC
REMOVAL
1. Deactivate the supplemental restraint system. 2. Remove the RH and LH A-pillar trim panels. 3.
Remove the cowl panel grille.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7534
Illustration 1 Of 2, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7535
Illustration 1 Of 2, Part 2
4. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Illustration 2 Of 2
5. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.
Item 4: Instrument Panel Defroster Grille Removal Note
1. CAUTION: To avoid damaging the sunload sensor electrical connector, remove the grille just
enough to access the connector.
Remove the instrument panel defroster grille.
Item 6: Instrument Panel Bolt Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7536
1. NOTE: The instrument panel bolt must be removed from outside the vehicle. Remove the
instrument panel bolt.
Item 10: Instrument Panel Bolt Removal Note
1. NOTE: Do not completely remove the instrument panel bolts.
Loosen the instrument panel bolts enough to allow the RH side of the instrument panel to be
moved away from the dash panel when the RH instrument panel bolts are removed.
Item 11: Instrument Panel Bolt Removal Note
1. CAUTION:
- Be sure the instrument panel is properly supported to avoid possible damage to the instrument
panel wiring and components.
- To avoid damage to the instrument panel wiring or components, do not use excessive force when
moving the instrument panel away from the dash panel.
NOTE: The instrument panel may be supported by installing threaded rods or equivalent, with the
same diameter and thread pitch, in place of the instrument panel support bolts.
Correctly support the instrument panel and remove the instrument panel support bolts to allow the
instrument panel to be pulled away from the dash panel.
INSTALLATION
1. To install, reverse the removal procedure.
Defrost Door
VACUUM CONTROL MOTOR - DEFROST DOOR
REMOVAL
1. Remove the plenum chamber.
2. Remove the components in the order indicated in the illustration and table.
Item 3: Vacuum Control Motor Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7537
1. Rotate the vacuum control motor until it clears the retaining arm and remove the vacuum control
motor.
INSTALLATION
1. To install, reverse the removal procedure.
Floor Door
VACUUM CONTROL MOTOR - FLOOR DOOR
REMOVAL
1. Deactivate the supplemental restraint system. 2. Remove the RH and LH A-pillar trim panels. 3.
Remove the cowl panel grille.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7538
Illustration 1 Of 2, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7539
Illustration 1 Of 2, Part 2
4. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Illustration 2 Of 2
5. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.
Item 4: Instrument Panel Defroster Grille Removal Note
1. CAUTION: To avoid damaging the sunload sensor electrical connector, remove the grille just
enough to access the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7540
Remove the instrument panel defroster grille.
Item 6: Instrument Panel Bolt Removal Note
1. NOTE: The instrument panel bolt must be removed from outside the vehicle.
Remove the instrument panel bolt.
Item 10: Instrument Panel Bolt Removal Note
1. NOTE: Do not completely remove the instrument panel bolts.
Loosen the instrument panel bolts enough to allow the RH side of the instrument panel to be
moved away from the dash panel when the RH instrument panel bolts are removed.
Item 11: Instrument Panel Bolt Removal Note
1. CAUTION:
- Be sure the instrument panel is properly supported to avoid possible damage to the instrument
panel wiring and components.
- To avoid damage to the instrument panel wiring or components, do not use excessive force when
moving the instrument panel away from the dash panel.
NOTE: The instrument panel may be supported by installing threaded rods or equivalent, with the
same diameter and thread pitch, in place of the instrument panel support bolts.
Correctly support the instrument panel and remove the instrument panel support bolts to allow the
instrument panel to be pulled away from the dash panel.
Item 17: Floor Door Vacuum Control Motor Removal Note
1. Rotate the vacuum control motor until it clears the retaining arm and remove the vacuum control
motor.
INSTALLATION
1. To install, reverse the removal procedure.
Panel Door
VACUUM CONTROL MOTOR - PANEL DOOR
REMOVAL
1. Lower the glove compartment door.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7541
2. Remove the components in the order indicated in the illustration and table.
Item 3: Vacuum Control Motor Removal Note
1. Rotate the vacuum control motor until it clears the retaining arm and remove the vacuum control
motor.
INSTALLATION
1. To install, reverse the removal procedure.
Air Inlet Door
VACUUM CONTROL MOTOR - AIR INLET DOOR
REMOVAL
1. Remove the air inlet duct.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7542
2. Remove the components in the order indicated in the illustration and table.
Item 2: Vacuum Control Motor Removal Note
1. Rotate the vacuum control motor until it clears the retaining arm and remove the vacuum control
motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7543
Air Door Actuator / Motor: Service and Repair Auxiliary Climate Control
Auxiliary Blend Door Actuator
BLEND DOOR ACTUATOR - AUXILIARY
REMOVAL
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Remove the LH quarter
trim panel.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Main Climate Control > Page 7544
Auxiliary Temperature Blend Door Actuator
TEMPERATURE BLEND DOOR ACTUATOR - AUXILIARY
REMOVAL
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Remove the LH quarter
trim panel.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair
Air Duct: Service and Repair
AIR DISTRIBUTION DUCTS
REMOVAL
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Page
7548
1. Remove the components in the order indicated in the illustration and table. If removing individual
components, carry out only the given steps.
Item 5: Floor Console Removal Note
1. Remove the front floor console.
Item 9: Instrument Panel Removal Note
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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Page
7549
Item 12: Heater Core and Evaporator Core Housing Removal Note
1. Remove the heater core and evaporator core housing.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
Air Register: Service and Repair
INSTRUMENT PANEL REGISTERS
REMOVAL
1. Remove the components in the order indicated in the illustration and table. To remove individual
components, carry out only the given steps.
Item 6: Instrument Cluster Finish Panel Removal Note
1. Remove the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7556
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7557
Ambient Temperature Sensor / Switch HVAC: Description and Operation
AMBIENT AIR TEMPERATURE SENSOR
The ambient air temperature sensor and bracket: is located in front of the condenser core.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the DATC module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7558
Ambient Temperature Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7559
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
REMOVAL
1. Remove the radiator grille.
2. Remove the components in the order listed in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay > Page 7568
View 151-11
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Blower Motor Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Blower Motor Relay > Page 7571
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Blower Motor Relay > Page 7572
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > High Speed Fan Control Relay
Blower Motor Relay: Testing and Inspection High Speed Fan Control Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > High Speed Fan Control Relay > Page 7575
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > High Speed Fan Control Relay > Page 7576
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > High Speed Fan Control Relay > Page 7577
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > High Speed Fan Control Relay > Page 7578
Blower Motor Relay: Testing and Inspection Auxiliary A/C Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > High Speed Fan Control Relay > Page 7579
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
View 151-11
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front Blower Motor Resistor Assembly
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front Blower Motor Resistor Assembly > Page 7585
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Page 7586
Blower Motor Resistor: Description and Operation
BLOWER MOTOR RESISTOR
The blower motor resistor: is located on the heater core and evaporator core housing near the blower motor.
- has three resistor elements mounted on the resistor board to provide four blower motor speeds.
- depending on the blower motor switch position, series resistance is added or bypassed in the
blower motor circuit to decrease or increase blower motor speed.
- has an overheating device (thermal limiter) that will open the resistor coil when the temperature
reaches approximately 184°C (363°F), interrupting the blower motor operation in all speeds except
high.
- is serviced as an assembly. The thermal limiter cannot be reset and is not serviceable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Page 7587
Front And Auxiliary Blower Motor Resistor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Main Climate Control
Blower Motor Resistor: Service and Repair Main Climate Control
BLOWER MOTOR RESISTOR - FRONT
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Main Climate Control > Page 7590
Blower Motor Resistor: Service and Repair Auxiliary Climate Control
BLOWER MOTOR RESISTOR - AUXILIARY
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and
Operation
Blower Motor Switch: Description and Operation
BLOWER MOTOR SWITCH
The blower motor switch controls blower motor speed by adding or bypassing resistors in the
blower motor switch resistor in all function selector switch positions except OFF.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7600
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7601
Cabin Temperature Sensor / Switch: Description and Operation
IN-VEHICLE TEMPERATURE SENSOR
The in-vehicle temperature sensor operates in the following manner: A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the heater core
and evaporator core housing and the in-vehicle temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the heater core and
evaporator core housing air stream to create a suction in the in-vehicle temperature sensor.
- The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7602
In-Vehicle Temperature Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7603
Cabin Temperature Sensor / Switch: Service and Repair
IN-VEHICLE TEMPERATURE SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Instrument Cluster Finish Panel Removal Note
1. Remove the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Air gap clearance..................................................................................................................................
..................................0.35-0.75 mm (0.014-0.030 in)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7608
Compressor Clutch: Description and Operation
A/C COMPRESSOR AND CLUTCH ASSEMBLY
NOTE: Internal A/C compressor components are not serviced separately. The Visteon SC115 A/C
compressor is serviced only as an assembly. The clutch plate, clutch pulley and bearing, and clutch
field coil are serviceable.
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
- Vehicles equipped with Visteon fixed scroll A/C compressors may experience rapid refrigerant
high side pressure fluctuations upon cold start-ups and/or after refrigerant system recharges.
These high side refrigerant fluctuations are characteristic of the Visteon fixed scroll compressor
and not an indication of a failing/failed A/C compressor.
The Visteon SC115 A/C compressor has the following characteristics: Tangential mount design three lugs.
- The single manifold block of the compressor manifold and tube assembly fits to the suction and
discharge ports. Two O-ring seals are used for sealing.
- An eccentric bushing is driven by the shaft of the A/C compressor.
- An orbiting scroll driven by the eccentric bushing compresses the refrigerant gas against the walls
of the fixed scroll.
- Single reed-type discharge valve mounted on the back of the fixed scroll. There are no suction
valves.
- Non-serviceable shaft seal fully supported on both sides by bearings.
- The A/C compressor uses PAG oil or equivalent. This oil contains special additives required for
the A/C compressor.
- The A/C compressor oil from vehicles equipped with an Visteon SC115 A/C compressor may
have some slightly dark-colored streaks while maintaining normal oil viscosity. This is normal for
this A/C compressor because of break-in wear of the scroll seals that can discolor the oil.
- Use standard oil matching procedures when installing new compressors.
The magnetic A/C clutch has the following characteristics: It drives the compressor shaft.
- When battery voltage is applied to the A/C compressor clutch field coil, the clutch plate and hub
assembly is drawn toward the A/C clutch pulley.
- The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together as
one unit, causing the compressor shaft to rotate.
- When battery voltage is removed from the A/C compressor clutch field coil, springs in the clutch
plate and hub assembly move the clutch plate away from the A/C clutch pulley.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7609
Compressor Clutch: Adjustments
AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT
1. Check the A/C clutch air gap at three equally spaced places between the clutch plate and the
A/C clutch pulley. 2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or
remove spacers between the clutch plate hub and the compressor shaft
until the clearance is within specification.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 05-17-8 > Sep > 05 > A/C - Drive
Belt Chirp When A/C Compressor Engages
Compressor Pulley: Customer Interest A/C - Drive Belt Chirp When A/C Compressor Engages
TSB 05-17-8
09/05/05
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a chirp
noise from the front end accessory drive (FEAD) belt when the A/C compressor is engaging.
ACTION Verify concern. Replace the A/C compressor clutch pulley, and set the clutch air gap to
the specification listed in this TSB (the Workshop Manual specification is being updated). Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Recover the refrigerant.
2. Remove the A/C compressor. Refer to Workshop Manual Section 412.
3. Using the special tool 412-098, hold the A/C clutch plate and remove the clutch nut.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C clutch hub spacer.
6. Remove the A/C compressor pulley snap ring.
CAUTION
DO NOT USE AIR TOOLS. DAMAGE TO THE A/C CLUTCH PULLEY OR A/C COMPRESSOR
MAY RESULT.
7. Using the special tool 412-001, remove the A/C clutch pulley.
8. Install the new A/C clutch pulley using special tool 412-109.
9. Reinstall the A/C compressor pulley snap ring.
10. Reinstall the original A/C clutch hub spacer.
11. Reinstall the A/C clutch disc and hub.
12. Using special tool 412-098, hold the A/C clutch plate and reinstall the A/C clutch nut. Tighten to
14 lb-ft (19 N.m).
13. Measure and adjust the clutch air gap to 0.010 - 0.024" (0.254 - 0.610 mm), by adding or
removing A/C clutch disc and hub spacers.
14. Reinstall the A/C compressor.
15. Recharge the system.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051708A 2002-2005 1.1 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 05-17-8 > Sep > 05 > A/C - Drive
Belt Chirp When A/C Compressor Engages > Page 7621
Explorer/Mountaineer 4.0L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708B 2002-2005 1.2 Hrs.
Explorer/Mountaineer 4.6L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708C 2003-2005 Aviator: 1.4 Hrs.
Replace The A/C Compressor Clutch Pulley (Do Not Use With 19700A, 19700A4, 19700AZU,
19700R)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D784 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 05-17-8 > Sep > 05 >
A/C - Drive Belt Chirp When A/C Compressor Engages
Compressor Pulley: All Technical Service Bulletins A/C - Drive Belt Chirp When A/C Compressor
Engages
TSB 05-17-8
09/05/05
CHIRP NOISE FROM FEAD BELT WHEN A/C COMPRESSOR IS ENGAGING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a chirp
noise from the front end accessory drive (FEAD) belt when the A/C compressor is engaging.
ACTION Verify concern. Replace the A/C compressor clutch pulley, and set the clutch air gap to
the specification listed in this TSB (the Workshop Manual specification is being updated). Refer to
the following Service Procedure.
SERVICE PROCEDURE
1. Recover the refrigerant.
2. Remove the A/C compressor. Refer to Workshop Manual Section 412.
3. Using the special tool 412-098, hold the A/C clutch plate and remove the clutch nut.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C clutch hub spacer.
6. Remove the A/C compressor pulley snap ring.
CAUTION
DO NOT USE AIR TOOLS. DAMAGE TO THE A/C CLUTCH PULLEY OR A/C COMPRESSOR
MAY RESULT.
7. Using the special tool 412-001, remove the A/C clutch pulley.
8. Install the new A/C clutch pulley using special tool 412-109.
9. Reinstall the A/C compressor pulley snap ring.
10. Reinstall the original A/C clutch hub spacer.
11. Reinstall the A/C clutch disc and hub.
12. Using special tool 412-098, hold the A/C clutch plate and reinstall the A/C clutch nut. Tighten to
14 lb-ft (19 N.m).
13. Measure and adjust the clutch air gap to 0.010 - 0.024" (0.254 - 0.610 mm), by adding or
removing A/C clutch disc and hub spacers.
14. Reinstall the A/C compressor.
15. Recharge the system.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051708A 2002-2005 1.1 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 05-17-8 > Sep > 05 >
A/C - Drive Belt Chirp When A/C Compressor Engages > Page 7627
Explorer/Mountaineer 4.0L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708B 2002-2005 1.2 Hrs.
Explorer/Mountaineer 4.6L SOHC: Replace The A/C Compressor Clutch Pulley (Do Not Use With
19700A, 19700A4, 19700AZU, 19700R)
051708C 2003-2005 Aviator: 1.4 Hrs.
Replace The A/C Compressor Clutch Pulley (Do Not Use With 19700A, 19700A4, 19700AZU,
19700R)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D784 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information >
Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7634
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7635
Compressor Clutch Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7636
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service
and Repair
Compressor Fitting HVAC: Service and Repair
COMPRESSOR MANIFOLD AND TUBE ASSEMBLY
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the A/C compressor.
2. Remove the components in the order indicated in the illustration and table.
Item 5: Compressor Manifold and Tube Assembly Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service
and Repair > Page 7640
1. Remove the lower compressor manifold and tube bracket nuts.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
CONDENSER CORE
NOTE: Installation of a new receiver/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 receiver/drier.
The 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7644
Condenser HVAC: Testing and Inspection
A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST
1. Recover the refrigerant.
2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to
the core tubes.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without
shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to
the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off
valve does not open
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C
evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before replacing the A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark.
- If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the
101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7645
Condenser HVAC: Service and Repair
CONDENSER CORE
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the air cleaner. 2. Remove the upper radiator sight shield. 3. Remove the suction
accumulator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7646
4. Remove the components in the order indicated in the illustration and table.
Item 8: Condenser Core Removal Note
1. Position the radiator towards the rear of the vehicle and remove the condenser core.
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Function Selector Switch Assembly
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Function Selector Switch Assembly > Page 7651
View 151-66
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views
Control Assembly: Connector Views
Function Selector Switch Assembly
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views > Page 7654
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views > Page 7655
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Connector Views > Page 7656
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Main Climate Control
Control Assembly: Description and Operation Main Climate Control
Manual Climate Control
FUNCTION SELECTOR SWITCH
The function selector switch combines a vacuum selector valve that determines air distribution and
an electrical switch to supply battery voltage to the A/C compressor circuit and the blower motor
circuit. When the function selector switch is in the MAX A/C, DEFROST, or FLOOR/DEFROST
positions, the A/C compressor will be operational regardless of the A/C request switch status.
CLIMATE CONTROL ASSEMBLY
The climate control assembly integrates the temperature control switch, A/C request button and
rear defog switch into a single unit.
The temperature control switch setting determines air temperature. Temperature selection is
accomplished with a potentiometer (temperature control switch) connected to the temperature
blend door actuator. Movement of the temperature control switch from COOL (blue) to WARM (red)
causes a corresponding movement of the temperature blend door and determines the air discharge
temperature that the air distribution system will maintain. The temperature control switch is an
integral part of the manual climate control assembly and cannot be separately replaced.
The A/C request switch determines A/C compressor operation, except when the function selector
switch is in the OFF, MAX, DEFROST, or FLOOR/DEFROST positions. The A/C request switch is
an integral part of the manual climate control assembly and cannot be separately replaced.
The rear defog button signals activation of the heated backlight and heated mirrors. The rear defog
button is an integral part of the manual climate control assembly and cannot be separately
replaced.
Dual Automatic Temperature Control
STEERING WHEEL AUDIO/CLIMATE CONTROL SWITCH
The steering wheel audio/climate control switch: is located on the right side of the steering wheel.
- allows the driver to adjust the passenger compartment temperature setting and manually override
the blower motor speed setting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Main Climate Control > Page 7659
Control Assembly: Description and Operation Auxiliary Climate Control
CONTROL ASSEMBLY
The auxiliary climate control system has dual controls for the driver and rear passengers consisting
of temperature, blower speed, and air distribution mode. The front auxiliary climate control
assembly is mounted in the overhead console. The rear auxiliary climate control assembly is
mounted in a separate overhead console positioned on the headliner above the second row
seating area.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Function Selector Switch
Function Selector Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Function Selector Switch > Page 7662
Front Auxiliary Climate Control Assembly
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Function Selector Switch > Page 7663
Rear Auxiliary Climate Control Assembly
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control
Control Assembly: Service and Repair Main Climate Control
Climate Control Assembly - DATC
CLIMATE CONTROL ASSEMBLY - DATC
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Climate Control Assembly - Manual
CLIMATE CONTROL ASSEMBLY - MANUAL
REMOVAL
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 7666
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 7667
Control Assembly: Service and Repair Auxiliary Climate Control
Auxiliary Climate Control Housing, Assembly
AUXILIARY CLIMATE CONTROL HOUSING, ASSEMBLY AND COMPONENTS
REMOVAL
NOTE:
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
- Clean and lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3.
Remove the LH quarter trim panel. 4. Detach the headliner duct from the auxiliary climate control
housing.
Illustration 1 Of 2
5. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 7668
Illustration 2 Of 2
6. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.
Item 3: Clamp Removal Note
1. Using a suitable tool, clamp-off and disconnect the heater hoses.
- After disconnecting the heater hoses, allow the coolant to drain from the auxiliary heater core to
avoid coolant spilling inside the passenger compartment.
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Fill the engine cooling system. 4. Evacuate, leak test and charge the
refrigerant system.
Front Auxiliary Climate Control Assembly
AUXILIARY CLIMATE CONTROL ASSEMBLY - FRONT
REMOVAL
1. Remove the overhead console.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 7669
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Rear Auxiliary Climate Control Assembly
AUXILIARY CLIMATE CONTROL ASSEMBLY - REAR
REMOVE
1. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Main Climate Control > Page 7670
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Electronic Automatic Temperature Control (EATC) Module
Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Electronic Automatic Temperature Control (EATC) Module > Page 7676
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Electronic Automatic Temperature Control (EATC) Module > Page 7677
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Page 7678
Control Module HVAC: Description and Operation
DATC MODULE
The DATC module: is located in the instrument panel.
- has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed
and diagnostic trouble codes (DTCs).
- utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble
codes (DTCs). These DTCs direct the technician to the inoperative component.
BLOWER MOTOR SPEED CONTROL
The blower speed control: is located on the heater core and evaporator core housing near the blower motor.
- converts low power signals from the DATC module to a high current, variable ground feed for the
blower motor.
- varies the blower motor speed and is controlled by the DATC module software.
- has a delay function to provide a gradual increase or decrease in blower motor speed under all
conditions.
- controls the integral high blower speed relay which is engaged when maximum fan speed is
selected.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Page 7679
Control Module HVAC: Service and Repair
BLOWER MOTOR SPEED CONTROL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service Precautions
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 the new O-ring seals. The use of any O-ring seals other than those specified in the Ford
Master Parts Catalog may result in intermittent leakage during vehicle operation.
- Support the female fitting with a wrench to prevent the tubes from twisting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service Precautions
> Page 7683
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 couplings.
- Use only the 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 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.
PEANUT FITTING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service Precautions
> Page 7684
The condenser core uses 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.
- Support the female fitting with a wrench to prevent twisting of the tubes.
- When correctly assembled the male and female fittings should be flush.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling
Coupler HVAC: Service and Repair Spring Lock Coupling
SPRING LOCK COUPLING
Spring Lock Coupling
SPECIAL TOOL(S)
DISCONNECT
1. Remove the A/C tube lock coupling clip, if equipped.
2. Fit the special 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7687
4. Pull the spring lock coupling fittings apart.
5. 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.
Remove the O-ring seals with a non-metallic tool.
6. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring;
this can cause axial scratches across
the O-ring seal grooves resulting in refrigerant leaks.
Remove the A/C tube lock coupling spring with a small hooked wire.
CLEANING
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7688
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) or equivalent. 5. Roll the pad on the tool and install it in a variable speed drill
motor.
6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to
prevent axial scratches which may cause
future leaks.
Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free
of scratches or foreign material.
7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves
and scratches are still present, install a new component.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7689
1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) or
equivalent.
3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those
specified in the Ford Master Parts Catalog may
result in intermittent leakage during vehicle operation.
Install the O-ring seals. Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7690
5. Install the A/C tube lock coupling clip.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7691
Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting
AIR CONDITIONING LINE (PEANUT) FITTING
DISCONNECT
1. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting.
Remove the nut from the peanut fitting.
2. Pull the peanut fitting apart.
3. 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.
Remove the O-ring seal with a non-metallic tool.
CONNECT
1. Clean all dirt or foreign material from the fittings.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling > Page 7692
2. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those
specified in the Ford Master Parts Catalog may
result in intermittent leakage during vehicle operation.
Install the O-ring seal. Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA
(Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent
meeting Ford specification WSH-M1C231-B.
4. NOTE: When correctly assembled, the male and female fittings should be flush.
Assemble the male and female fittings together.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Page 7693
Remover, Refrigerant Coupling Spring
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 04-18-3 > Sep > 04 > A/C - Low Rpm Hooting Noise
Evaporator Case: Customer Interest A/C - Low Rpm Hooting Noise
TSB 04-18-3
09/20/04
A/C HOOT NOISE WHILE DRIVING
FORD: 2002-2005 Explorer
MERCURY: 2002-2005 Mountaineer
ISSUE
Some 2002-2005 Explorer 4dr/Mountaineer vehicles, without auxiliary rear air conditioning, may
exhibit a brief hooting noise while the A/C is on. The noise may be described as a whistle coming
from the vehicles front A/C vents. The condition occurs during light load acceleration at low speeds
(1000-1300 RPM), with ambient temperatures of 85°F (29°C) or higher and high humidity.
THIS HOOT NOISE IS A SEPARATE ISSUE FROM BLEND DOOR SHAFT WHISTLE (TSB
03-07-04).
ACTION
Install a revised evaporator case. Refer to the following Service Procedure.
NOTE
THIS REPAIR SHOULD NOT BE PERFORMED ON VEHICLES EQUIPPED WITH AUXILIARY
REAR AIR CONDITIONING.
SERVICE PROCEDURE
NOTE
ALL WORKSHOP MANUAL PROCEDURES MUST BE FOLLOWED IN THEIR ENTIRETY.
FAILURE TO REMOVE AND REINSTALL COMPONENTS CORRECTLY MAY RESULT IN
FUTURE A/C CONCERNS AND/OR INTERIOR RATTLE ISSUES.
1. Recover the refrigerant from the vehicle prior to removal of evaporator case assembly. Refer to
Air Conditioning (A/C) System Recovery, Evacuation and Charging in Section (412-00) of the
Workshop Manual.
2. Refer to Workshop Manual Section (412-00) for evaporator case removal instructions and
remove the evaporator case from the vehicle.
NOTE
BE VERY CAREFUL REMOVING THE EVAPORATOR CASE FROM THE VEHICLE. VERIFY
THAT ALL VACUUM LINES AND GROUND STRAPS ARE DISCONNECTED PRIOR TO
REMOVAL.
3. Remove all components from the vehicle's existing evaporator case and reinstall them on the
new case prior to case installation into the vehicle.
MANUAL SYSTEM COMPONENTS
^ Actuator
^ Vacuum Motor
^ Inlet Assembly
^ Inlet Bracket
^ Floor Ducts
^ Resistor
^ Blower Motor
^ Vacuum Harness
^ Wire Harness
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 04-18-3 > Sep > 04 > A/C - Low Rpm Hooting Noise > Page 7702
^ Heater Core and Seal Assembly
^ Heater Core Cover
^ Heater Core Dash Seal
^ Heater Tube Cover
^ Drain Tube Dash Seal
ELECTRONIC SYSTEM COMPONENTS
^ Actuators
^ VBC
^ Blower Motor
^ Vacuum Harness
^ Wire Harness
^ Heater Core and Seal Assembly
^ Heater Core Cover
^ Heater Tube Cover
^ Inlet Assembly Inlet Bracket
^ Floor Ducts
^ Heater Core and Dash Seal
^ Drain Tube Dash Seal
^ Aspirator Tube
^ Solenoid
4. Install the revised evaporator case into the vehicle.
PARTS BLOCK
LABOR OPERATION CLAIMING CHART
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 04-18-3 > Sep > 04 > A/C - Low Rpm Hooting Noise > Page 7703
CONDITION
BASIC PART NO. CODE
19850 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 04-18-3 > Sep > 04 > A/C - Low Rpm Hooting Noise
Evaporator Case: All Technical Service Bulletins A/C - Low Rpm Hooting Noise
TSB 04-18-3
09/20/04
A/C HOOT NOISE WHILE DRIVING
FORD: 2002-2005 Explorer
MERCURY: 2002-2005 Mountaineer
ISSUE
Some 2002-2005 Explorer 4dr/Mountaineer vehicles, without auxiliary rear air conditioning, may
exhibit a brief hooting noise while the A/C is on. The noise may be described as a whistle coming
from the vehicles front A/C vents. The condition occurs during light load acceleration at low speeds
(1000-1300 RPM), with ambient temperatures of 85°F (29°C) or higher and high humidity.
THIS HOOT NOISE IS A SEPARATE ISSUE FROM BLEND DOOR SHAFT WHISTLE (TSB
03-07-04).
ACTION
Install a revised evaporator case. Refer to the following Service Procedure.
NOTE
THIS REPAIR SHOULD NOT BE PERFORMED ON VEHICLES EQUIPPED WITH AUXILIARY
REAR AIR CONDITIONING.
SERVICE PROCEDURE
NOTE
ALL WORKSHOP MANUAL PROCEDURES MUST BE FOLLOWED IN THEIR ENTIRETY.
FAILURE TO REMOVE AND REINSTALL COMPONENTS CORRECTLY MAY RESULT IN
FUTURE A/C CONCERNS AND/OR INTERIOR RATTLE ISSUES.
1. Recover the refrigerant from the vehicle prior to removal of evaporator case assembly. Refer to
Air Conditioning (A/C) System Recovery, Evacuation and Charging in Section (412-00) of the
Workshop Manual.
2. Refer to Workshop Manual Section (412-00) for evaporator case removal instructions and
remove the evaporator case from the vehicle.
NOTE
BE VERY CAREFUL REMOVING THE EVAPORATOR CASE FROM THE VEHICLE. VERIFY
THAT ALL VACUUM LINES AND GROUND STRAPS ARE DISCONNECTED PRIOR TO
REMOVAL.
3. Remove all components from the vehicle's existing evaporator case and reinstall them on the
new case prior to case installation into the vehicle.
MANUAL SYSTEM COMPONENTS
^ Actuator
^ Vacuum Motor
^ Inlet Assembly
^ Inlet Bracket
^ Floor Ducts
^ Resistor
^ Blower Motor
^ Vacuum Harness
^ Wire Harness
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 04-18-3 > Sep > 04 > A/C - Low Rpm Hooting Noise >
Page 7709
^ Heater Core and Seal Assembly
^ Heater Core Cover
^ Heater Core Dash Seal
^ Heater Tube Cover
^ Drain Tube Dash Seal
ELECTRONIC SYSTEM COMPONENTS
^ Actuators
^ VBC
^ Blower Motor
^ Vacuum Harness
^ Wire Harness
^ Heater Core and Seal Assembly
^ Heater Core Cover
^ Heater Tube Cover
^ Inlet Assembly Inlet Bracket
^ Floor Ducts
^ Heater Core and Dash Seal
^ Drain Tube Dash Seal
^ Aspirator Tube
^ Solenoid
4. Install the revised evaporator case into the vehicle.
PARTS BLOCK
LABOR OPERATION CLAIMING CHART
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 04-18-3 > Sep > 04 > A/C - Low Rpm Hooting Noise >
Page 7710
CONDITION
BASIC PART NO. CODE
19850 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Page 7711
Evaporator Case: Description and Operation
HEATER CORE AND EVAPORATOR CORE HOUSING
The heater core and evaporator core housing directs airflow from the blower motor through the
evaporator core and heater core. All airflow from the blower motor passes through the evaporator
core. The airflow is then directed through or around the heater core by the temperature blend
door(s). Vehicles equipped with DATC use a partitioned heater core and evaporator core housing
with two electric actuator-positioned temperature blend doors. This allows for separate
temperatures to be selected for the driver and passenger sides of the passenger compartment.
Manual systems use a single electric actuator-positioned temperature blend door to direct airflow
through or around the heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Auxiliary Climate Control
Evaporator Case: Service and Repair Auxiliary Climate Control
AUXILIARY CLIMATE CONTROL HOUSING, ASSEMBLY AND COMPONENTS
REMOVAL
NOTE:
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
- Clean and lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3.
Remove the LH quarter trim panel. 4. Detach the headliner duct from the auxiliary climate control
housing.
Illustration 1 Of 2
5. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7714
Illustration 2 Of 2
6. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.
Item 3: Clamp Removal Note
1. Using a suitable tool, clamp-off and disconnect the heater hoses.
- After disconnecting the heater hoses, allow the coolant to drain from the auxiliary heater core to
avoid coolant spilling inside the passenger compartment.
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Fill the engine cooling system. 4. Evacuate, leak test and charge the
refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7715
Evaporator Case: Service and Repair Main Climate Control
HEATER CORE AND EVAPORATOR CORE HOUSING, ASSEMBLY AND COMPONENTS
REMOVAL
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
- Lubricate the coolant hoses with plain water only if needed.
1. Recover the refrigerant. 2. 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
3. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7716
Item 5: Vacuum Connector Removal Note
1. Disconnect the vacuum line connectors in the engine compartment.
2. Detach the grommet and push the vacuum lines into the passenger compartment.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > A/C - Evaporator Core Replacement
Evaporator Core: Technical Service Bulletins A/C - Evaporator Core Replacement
TSB 04-19-6
09/22/04
EVAPORATOR CORE REPLACEMENT
FORD: 2002-2005 Explorer
MERCURY: 2002-2005 Mountaineer
ISSUE
Should it become necessary to replace the evaporator core on a 2002-2005 Explorer 4dr or
Mountaineer vehicle, the evaporator core can now be serviced as a separate unit. It is no longer
necessary to replace the entire housing assembly.
ACTION
Refer to the following Service Procedure.
SERVICE PROCEDURE
1. Remove the evaporator housing from the vehicle. Refer to Workshop Manual Section (412-00).
2. Remove the ten (10) evaporator core cover bolts.
3. Remove the evaporator core cover and discard the rope seal.
4. Install the new evaporator core into the housing.
5. Using Motorcraft RTV Silicone Sealant (TA-31) carefully apply a 1/8" bead around the entire
evaporator housing groove joint (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > A/C - Evaporator Core Replacement > Page 7721
6. Reinstall the evaporator core cover. Torque the ten (10) cover bolts using a diagonal pattern to
distribute the RTV Sealant evenly.
7. Refer to the Workshop Manual Section 412-00 and reinstall the evaporator case into the vehicle.
PARTS BLOCK
LABOR OPERATION CLAIMING CHART
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
19860 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Main Climate Control
Evaporator Core: Description and Operation Main Climate Control
EVAPORATOR CORE
NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The evaporator core is the plate/fin type with a unique refrigerant flow path. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator
core inlet tube, continues over to the remaining five plate/fin sections, and then moves out of the
evaporator core through the evaporator core outlet tube.
- This W-pass flow pattern accelerates the flow of refrigerant and oil through the evaporator core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Main Climate Control > Page 7724
Evaporator Core: Description and Operation Auxiliary Climate Control
EVAPORATOR CORE
NOTE: The auxiliary evaporator core is not separately serviceable. It is serviced only with the
auxiliary climate control housing.
The auxiliary climate control system uses a rear evaporator core which operates in the same
manner as the front evaporator core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7725
Evaporator Core: Testing and Inspection
A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST
1. Recover the refrigerant.
2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to
the core tubes.
Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system.
3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air
Conditioning Test Fitting Set to the evaporator or condenser tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without
shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to
the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off
valve does not open
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C
evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before replacing the A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark.
- If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the
101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation
Expansion Block/Orifice Tube: Description and Operation
EVAPORATOR CORE ORIFICE TUBE
NOTE: A new evaporator core orifice tube 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 is located in the condenser to evaporator line.
- 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 evaporator
core orifice tube.
- O-ring seals on the evaporator core orifice tube prevent the high-pressure liquid refrigerant from
bypassing the evaporator core orifice tube.
- it can be accessed through a fitting located near the middle of the condenser to evaporator line.
- Adjustment or service cannot be carried out to the evaporator core orifice tube. A new evaporator
core orifice must be installed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Page 7729
Expansion Block/Orifice Tube: Service and Repair
EVAPORATOR CORE ORIFICE
SPECIAL TOOL(S)
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the condenser to evaporator line.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Evaporator Core Orifice Removal Note
1. Inspect the evaporator core orifice for damage before attempting to remove it from the line.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Page 7730
2. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while
rotating the tool body to remove the evaporator
core orifice.
3. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice.
Hold the T-handle stationary while rotating the
tool body to remove the evaporator core orifice.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Evaporator Core Orifice Installation Note
1. Lubricate the evaporator core orifice O-rings with clean PAG oil and install the evaporator core
orifice using the special tool.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Page 7731
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Customer Interest for Expansion Valve: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From Vehicle
Rear
Expansion Valve: Customer Interest A/C - Moan/Buzz/Groan Noise From Vehicle Rear
TSB 04-24-6
12/13/04
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles built before
10/15/2004 equipped with rear air conditioning may exhibit a whistle/moan/groan/buzz noise
coming from the rear evaporator core area. This condition is usually intermittent and is typically
present on light throttle application.
ACTION Inspect A/C lines for possible grounding. If the source of the noise cannot be pinpointed
through normal diagnostics, replace the rear thermostatic expansion valve (TXV).
SERVICE PROCEDURE
NOTE
FOR STEPS 1, 5 AND 6, REFER TO WORKSHOP MANUAL SECTION 412-00.
1. Recover the refrigerant.
2. Disconnect the LH quarter trim panel and gently pull cover back to expose rear lxv. Refer to
Workshop Manual Section 501-01.
NOTE
IT IS NOT NECESSARY TO REMOVE THE LH QUARTER TRIM PANEL FROM THE VEHICLE.
3. Remove the rear TXV.
4. To install, reverse the removal procedure. Torque the rear TXV nut to 17 lb-ft (23 N.m).
5. Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042406A Replace The Rear 1.5 Hrs.
Thermostatic Expansion Valve (Includes Time To Inspect Lines And Recover, Evacuate And
Charge The Refrigerant System)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Customer Interest for Expansion Valve: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From Vehicle
Rear > Page 7740
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 41
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Expansion Valve: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From
Vehicle Rear
Expansion Valve: All Technical Service Bulletins A/C - Moan/Buzz/Groan Noise From Vehicle Rear
TSB 04-24-6
12/13/04
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles built before
10/15/2004 equipped with rear air conditioning may exhibit a whistle/moan/groan/buzz noise
coming from the rear evaporator core area. This condition is usually intermittent and is typically
present on light throttle application.
ACTION Inspect A/C lines for possible grounding. If the source of the noise cannot be pinpointed
through normal diagnostics, replace the rear thermostatic expansion valve (TXV).
SERVICE PROCEDURE
NOTE
FOR STEPS 1, 5 AND 6, REFER TO WORKSHOP MANUAL SECTION 412-00.
1. Recover the refrigerant.
2. Disconnect the LH quarter trim panel and gently pull cover back to expose rear lxv. Refer to
Workshop Manual Section 501-01.
NOTE
IT IS NOT NECESSARY TO REMOVE THE LH QUARTER TRIM PANEL FROM THE VEHICLE.
3. Remove the rear TXV.
4. To install, reverse the removal procedure. Torque the rear TXV nut to 17 lb-ft (23 N.m).
5. Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042406A Replace The Rear 1.5 Hrs.
Thermostatic Expansion Valve (Includes Time To Inspect Lines And Recover, Evacuate And
Charge The Refrigerant System)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Expansion Valve: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From
Vehicle Rear > Page 7746
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 41
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service
Bulletins > Page 7747
Expansion Valve: Description and Operation
THERMOSTATIC EXPANSION VALVE
A thermostatic expansion valve automatically regulates the flow of refrigerant into the auxiliary
evaporator core. It is also the dividing point in the system between low- and high-pressure sides.
The temperature sensing bulb measures the temperature of the refrigerant in the suction line and
transmits it to the thermostatic expansion valve. This temperature variation regulates the refrigerant
flow to the auxiliary evaporator core. When the bulb senses a high temperature, the thermostatic expansion valve opens and floods
refrigerant through the auxiliary evaporator core.
- When the bulb senses a low temperature, the thermostatic expansion valve starts closing to shut
off the refrigerant to the auxiliary evaporator core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Description and
Operation
Heater Control Valve: Description and Operation
HEATER CONTROL VALVE
The heater control valve is actuated by the heater control valve vacuum switch (manual climate
control) or the heater control valve vacuum control circuit (DATC). when the heater control valve is
closed (full vacuum), coolant flow through the heater core is shut off and A/C cooling efficiency is
increased.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Description and
Operation > Page 7751
Heater Control Valve: Service and Repair
HEATER CONTROL VALVE AND HEATER HOSES
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. If removing any component
other than the heater control valve, drain the engine coolant. 3. If removing the heater control valve
only, clamp off the heater hoses at the heater control valve inlet and outlet.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Description and
Operation > Page 7752
4. Remove the components in the order indicated in the illustration and table. To remove individual
components, carry out only the given steps.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7761
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
7762
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7768
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7769
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 7770
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Operation > Auxiliary Climate Control
Heater Core: Description and Operation Auxiliary Climate Control
HEATER CORE
The auxiliary climate control system uses a rear heater core which operates in the same manner as
the front heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Operation > Auxiliary Climate Control > Page 7773
Heater Core: Description and Operation Main Climate Control
HEATER CORE
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
HEATER CORE AND EVAPORATOR CORE HOUSING
The heater core and evaporator core housing directs airflow from the blower motor through the
evaporator core and heater core. All airflow from the blower motor passes through the evaporator
core. The airflow is then directed through or around the heater core by the temperature blend
door(s). Vehicles equipped with DATC use a partitioned heater core and evaporator core housing
with two electric actuator-positioned temperature blend doors. This allows for separate
temperatures to be selected for the driver and passenger sides of the passenger compartment.
Manual systems use a single electric actuator-positioned temperature blend door to direct airflow
through or around the heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Operation > Page 7774
Heater Core: Testing and Inspection
Heater Core
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. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were
good and did not require replacement. If a heater
core leak is suspected, the heater core must be tested by carrying out the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking
the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core-Plugged
WARNING: The heater core inlet 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 inlet and
outlet hose to see if they are hot.
If the inlet hose is not hot: -
the heater control valve may be stuck closed.
- the thermostat is not working correctly.
If the outlet hose is not hot: the heater core may have an air pocket.
- the heater core may be restricted or plugged.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Clamp off the heater hoses.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater 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 ET-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 perform the bench test.
Heater Core - Bench Test
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Operation > Page 7775
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, replace the heater core.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary Climate Control
Heater Core: Service and Repair Auxiliary Climate Control
HEATER CORE - AUXILIARY
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Using suitable tools,
clamp-off the underbody heater hoses at the floorpan bracket.
Illustration 1 Of 3
3. Illustration 1 of 3. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7778
Illustration 2 Of 3
4. Illustration 2 of 3. Remove the components in the order indicated in illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7779
Illustration 3 Of 3
5. Illustration 3 of 3. Remove the components in the order indicated in the illustration and table.
Item 4: Line Bracket Screw Removal Note
1. The screw and line bracket are located inside the vehicle above the floorpan line bracket.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7780
Heater Core: Service and Repair Main Climate Control
Front Heater Core
HEATER CORE - FRONT
REMOVAL
NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is
removed from the vehicle.
1. Remove the heater core and evaporator core housing.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7781
Heater Core and Evaporator Core Housing
HEATER CORE AND EVAPORATOR CORE HOUSING, ASSEMBLY AND COMPONENTS
REMOVAL
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
- Lubricate the coolant hoses with plain water only if needed.
1. Recover the refrigerant. 2. 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
3. Remove the components in the order indicated in the illustration and table.
Item 5: Vacuum Connector Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7782
1. Disconnect the vacuum line connectors in the engine compartment.
2. Detach the grommet and push the vacuum lines into the passenger compartment.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7791
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7792
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7798
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7799
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 05-9-5 > May > 05 > Body - License Plate Shield Cracked/Broken
License Plate Bracket: All Technical Service Bulletins Body - License Plate Shield Cracked/Broken
TSB 05-9-5
05/16/05
LICENSE PLATE SHIELD CRACKS OR BREAKS - VEHICLES BUILT BEFORE 10/14/2004 WITH
XLS TRIM
FORD: 2003-2005 Explorer
ISSUE Some 2003-2005 Explorer 4dr vehicles built before 10/14/2004 and with XLS trim, may
exhibit the license plate shield cracking or breaking in cold temperatures. This may be due to the
liftgate release handle coming in contact with the shield during use.
ACTION
If the license plate shield is damaged, replace the shield and the rear liftgate release handle.
SERVICE PROCEDURE
1. Replace the liftgate release handle per Section 501-14 of the Workshop Manual.
LICENSE PLATE SHIELD REPLACEMENT
1. Remove the four (4) attachment bolts and remove the license plate shield (Figure 1).
2. Install the replacement shield and torque the bolts to 108 lb-in (12 N.m).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050905A 2003-2005 Explorer 4 Door 0.4 Hr.
Replace The Rear Liftgate Release Handle And License Plate Shield (Do Not Use With 46404B,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 05-9-5 > May > 05 > Body - License Plate Shield Cracked/Broken
> Page 7805
46404B10, P42D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7843400 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 05-9-5 > May > 05 > Body - License Plate Shield Cracked/Broken
> Page 7811
46404B10, P42D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7843400 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Climate Control
Heater Hose: Service and Repair Auxiliary Climate Control
Front Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE - FRONT
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Drain the engine coolant.
3. Remove the RH running board brackets.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7814
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine coolant level.
Rear Auxiliary Heater Outlet and Inlet Line
AUXILIARY HEATER OUTLET AND INLET LINE - REAR
REMOVAL
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Drain the engine coolant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7815
3. Remove the spare tire.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine coolant level.
Item 12 & 11: Auxiliary Heater Line Installation Note
1. Clean and lubricate the coolant hoses with plain water only if needed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7816
Heater Hose: Service and Repair Main Climate Control
HEATER CONTROL VALVE AND HEATER HOSES
REMOVAL
NOTE: Lubricate the coolant hoses with plain water only if needed.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. If removing any component
other than the heater control valve, drain the engine coolant. 3. If removing the heater control valve
only, clamp off the heater hoses at the heater control valve inlet and outlet.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Climate Control > Page 7817
4. Remove the components in the order indicated in the illustration and table. To remove individual
components, carry out only the given steps.
INSTALLATION
1. To install, reverse the removal procedure. 2. Fill the engine cooling system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation
High Pressure Safety Valve HVAC: Description and Operation
A/C COMPRESSOR PRESSURE RELIEF VALVE
An A/C compressor pressure relief valve is incorporated in the compressor manifold and tube
assembly to: relieve unusually high refrigerant system discharge pressure buildups.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From Vehicle
Rear
Hose/Line HVAC: Customer Interest A/C - Moan/Buzz/Groan Noise From Vehicle Rear
TSB 04-24-6
12/13/04
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles built before
10/15/2004 equipped with rear air conditioning may exhibit a whistle/moan/groan/buzz noise
coming from the rear evaporator core area. This condition is usually intermittent and is typically
present on light throttle application.
ACTION Inspect A/C lines for possible grounding. If the source of the noise cannot be pinpointed
through normal diagnostics, replace the rear thermostatic expansion valve (TXV).
SERVICE PROCEDURE
NOTE
FOR STEPS 1, 5 AND 6, REFER TO WORKSHOP MANUAL SECTION 412-00.
1. Recover the refrigerant.
2. Disconnect the LH quarter trim panel and gently pull cover back to expose rear lxv. Refer to
Workshop Manual Section 501-01.
NOTE
IT IS NOT NECESSARY TO REMOVE THE LH QUARTER TRIM PANEL FROM THE VEHICLE.
3. Remove the rear TXV.
4. To install, reverse the removal procedure. Torque the rear TXV nut to 17 lb-ft (23 N.m).
5. Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042406A Replace The Rear 1.5 Hrs.
Thermostatic Expansion Valve (Includes Time To Inspect Lines And Recover, Evacuate And
Charge The Refrigerant System)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From Vehicle
Rear > Page 7829
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 41
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise
Hose/Line HVAC: Customer Interest A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter Noise > Page
7834
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From
Vehicle Rear
Hose/Line HVAC: All Technical Service Bulletins A/C - Moan/Buzz/Groan Noise From Vehicle Rear
TSB 04-24-6
12/13/04
NOISE DURING A/C OPERATION FROM REAR OF VEHICLE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles built before
10/15/2004 equipped with rear air conditioning may exhibit a whistle/moan/groan/buzz noise
coming from the rear evaporator core area. This condition is usually intermittent and is typically
present on light throttle application.
ACTION Inspect A/C lines for possible grounding. If the source of the noise cannot be pinpointed
through normal diagnostics, replace the rear thermostatic expansion valve (TXV).
SERVICE PROCEDURE
NOTE
FOR STEPS 1, 5 AND 6, REFER TO WORKSHOP MANUAL SECTION 412-00.
1. Recover the refrigerant.
2. Disconnect the LH quarter trim panel and gently pull cover back to expose rear lxv. Refer to
Workshop Manual Section 501-01.
NOTE
IT IS NOT NECESSARY TO REMOVE THE LH QUARTER TRIM PANEL FROM THE VEHICLE.
3. Remove the rear TXV.
4. To install, reverse the removal procedure. Torque the rear TXV nut to 17 lb-ft (23 N.m).
5. Lubricate the refrigerant system with the correct amount of clean PAG oil.
6. Evacuate, leak test and charge the refrigerant system.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042406A Replace The Rear 1.5 Hrs.
Thermostatic Expansion Valve (Includes Time To Inspect Lines And Recover, Evacuate And
Charge The Refrigerant System)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-24-6 > Dec > 04 > A/C - Moan/Buzz/Groan Noise From
Vehicle Rear > Page 7840
DEALER CODING
CONDITION
BASIC PART NO. CODE
19849 41
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter
Noise
Hose/Line HVAC: All Technical Service Bulletins A/C - Underhood - Buzz or Flutter Noise
Article No. 03-5-2
03/17/03
NOISE - "BUZZ" OR "FLUTTER" NOISE FROM INSTRUMENT PANEL/UNDERHOOD AREA
DURING COLD WEATHER, LIGHT LOAD AND THROTTLE TIP IN-VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some vehicles equipped with a 4.0L SOHC engine may exhibit a Buzz/Flutter sound from
the right side of the Instrument Panel/Underhood Engine Compartment area. This noise may be
heard under cold weather conditions when the engine is under a light load or throttle tip in. The
noise involves the air intake housing interfering with the A/C lines routed under the rear corner of
the housing. The housing is located at the right hand forward section of the engine compartment.
ACTION The A/C lines must be isolated from contacting the air intake housing. Use 3 mm thick
urethane tape, Rotunda Part 164-R4902 or equivalent, as found in the dealer squeak and rattle
special tool kit, Part Number 164-R9400 to isolate the lines from contacting the air intake housing.
Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Section 303-12: Intake Air Distribution and Filtering - Removal and Installation.
1. Remove air intake housing (Figure 1).
2. Install tape to insulate (Figure 1).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-5-2 > Mar > 03 > A/C - Underhood - Buzz or Flutter
Noise > Page 7845
NOTE
ISOLATION PAD LOCATION ON AIR INTAKE HOUSING MAY VARY DEPENDING ON A/C LINE
ROUTING.
3. Reinstall air intake housing.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030502A Install Urethane Tape On 0.5 Hr.
Air Intake Housing (Includes Time To Test Drive)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19D850 07
OASIS CODES: 107000, 504000, 702000, 702100, 702300, 703000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation > Main Climate Control
Hose/Line HVAC: Description and Operation Main Climate Control
REFRIGERANT LINES
NOTE: Installation of a new receiver/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 receiver/drier.
The compressor manifold and tube assembly is attached to the A/C compressor, is sealed 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 high pressure cutoff switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C high pressure
cutoff switch can be removed without discharging the A/C system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation > Main Climate Control > Page 7848
Hose/Line HVAC: Description and Operation Auxiliary Climate Control
UNDERBODY AUXILIARY A/C LINES
The underbody auxiliary A/C lines carry refrigerant to the auxiliary A/C evaporator inlet line, and
away from the auxiliary A/C evaporator outlet line. The auxiliary underbody lines have the following
characteristics. The underbody auxiliary A/C evaporator inlet line consists of two separately serviceable pieces.
- The fore auxiliary A/C evaporator inlet line carries high pressure refrigerant liquid from the
condenser to evaporator line to the aft auxiliary A/C evaporator inlet line.
- The aft auxiliary A/C evaporator inlet line carries high pressure refrigerant liquid from the fore
auxiliary A/C evaporator inlet line to the auxiliary evaporator inlet.
- The underbody auxiliary A/C evaporator outlet line consists of two separately serviceable pieces.
- The aft auxiliary A/C evaporator outlet line carries refrigerant vapor from the auxiliary A/C
evaporator outlet to the fore auxiliary A/C evaporator outlet line.
- The fore auxiliary A/C evaporator outlet line carries refrigerant vapor from the aft auxiliary A/C
evaporator inlet line to the manifold and tube assembly.
UNDERBODY HEATER LINES
The underbody auxiliary heater lines have the following features. The underbody auxiliary heater inlet line consists of two separately serviceable assemblies.
- The fore underbody auxiliary heater inlet line is a steel tube assembly that carries coolant from
the front heater core inlet line to the aft underbody auxiliary heater inlet line.
- The aft underbody auxiliary heater inlet line carries coolant from the fore underbody heater inlet
line to the auxiliary heater core.
- The aft underbody auxiliary heater inlet line consists of a steel tube with formed rubber hoses at
each end. The rubber hoses are attached and sealed to the tube using constant tension pop
clamps.
- The aft underbody auxiliary heater outlet line carries coolant from the auxiliary heater core to the
fore underbody auxiliary heater outlet line.
- The aft underbody auxiliary heater outlet line consists of a steel tube with formed rubber hoses at
each end. The rubber hoses are attached and sealed to the tube using constant tension pop
clamps.
- The fore underbody auxiliary heater outlet line is a steel tube assembly that carries coolant from
the aft underbody heater outlet line to the front heater core outlet line.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control
Hose/Line HVAC: Service and Repair Auxiliary Climate Control
Front Auxiliary Evaporator Outlet and Inlet Line
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT
REMOVAL
NOTE:
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3.
Remove the RH running board brackets.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7851
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Rear Auxiliary Evaporator Outlet and Inlet Line
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR
REMOVAL
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7852
NOTE:
- Installation of a new accumulator is not required when repairing the air conditioning system
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3.
Remove the spare tire.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7853
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7854
Hose/Line HVAC: Service and Repair Main Climate Control
Evaporator Outlet Line
EVAPORATOR OUTLET LINE
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil, must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the air cleaner and air cleaner outlet tube. 2. Recover the refrigerant. 3. Disconnect the
RH wheel speed sensor electrical connector.
4. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7855
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system.
Condenser to Evaporator Line
CONDENSER TO EVAPORATOR LINE
REMOVAL
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
- New O-ring seals, lubricated in clean PAG oil must be installed before reconnecting any A/C
fitting which has been disconnected.
1. Remove the air cleaner and air cleaner outlet tube. 2. Remove the suction accumulator. 3.
Recover the refrigerant.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct
amount of clean PAG oil.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Auxiliary Climate Control > Page 7856
3. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair
Housing Assembly HVAC: Service and Repair
PLENUM CHAMBER, ASSEMBLY AND COMPONENTS
REMOVAL
1. Remove the center instrument panel finish panel. 2. Remove the defroster duct. 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 components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Page 7860
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Capacity without auxiliary climate control.............................................................................................
..........................................................0.96 kg (34 oz)
Capacity with auxiliary climate control..................................................................................................
..........................................................1.59 kg (56 oz)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 7865
Refrigerant: Fluid Type Specifications
Refrigerant Type ..................................................................................................................................
.......................................................... R134a, YN-19
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
7866
Refrigerant: Service Precautions
CAUTION:
- If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12
recovery/recycling equipment.
- Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If
the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all
the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other
cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful
in removing small traces of contamination from the air that might affect the leak detector.
- Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the
engine.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
7867
Refrigerant: Description and Operation
REFRIGERANT SYSTEM DYE
Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will
dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye
after flushing or filtering the refrigerant system because a new suction accumulator is installed as
part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if
more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation,
hose rupture or other damage.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection
Refrigerant: Testing and Inspection Electronic Leak Detection
ELECTRONIC LEAK DETECTION
Refrigerent Leak Detector
SPECIAL TOOL(S)
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be
carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate
this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner,
or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is
very helpful in removing small traces of contamination from the air that might affect the leak
detector.
1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant.
- Repair the system.
- Test the system for normal operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 7870
Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection
FLUORESCENT DYE LEAK DETECTION
Special Tool(s)
SPECIAL TOOL(S)
NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the
refrigerant system from the factory. The location of leaks can be pinpointed by the bright
yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist,
make sure to inspect each component, line, and fitting in the refrigerant system for a leak.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 7871
1. Check for leaks using the special tool.
- Inspect all components, lines, and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate
and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of
fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the
leak with the special tool.
Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
NOTE:
- Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers
instructions on evacuation of any non-condensable gasses from the hoses.
- Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service
center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way
check valve that will prevent refrigerant system recovery and evacuation.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the
engine off.
1. Install an R-134a A/C refrigerant service center or a manifold and gauge set.
2. Verify that the valves on the special tool are closed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 7872
3. Fill the special tool reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the special tool
between the low-pressure service gauge port valve and the R-134a refrigerant service center or
manifold gauge set. 5. Open all valves and inject the fluorescent dye into the refrigerant system 6.
When fluorescent dye injection is complete, close all valves. 7. Recover the refrigerant from the
R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure
service gauge port valve and the R- 134a A/C refrigerant service center or manifold
gauge set.
Fluorescent Dye Injection - Using a Dye Injector Loop Kit
NOTE:
- Before using the R-134a fluorescent dye injector for the first time, refer to the equipment
manufacturers instructions on evacuation of non-condensable gasses from the hoses.
- Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C.
1. Verify that the valves on the special tool are closed.
2. Fill the special tool reservoir with 7 ml (0.25 oz) of fluorescent dye. 3. Install the special tool
between the high-pressure and low-pressure service gauge port valves.
4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt
before starting the engine.
Start the engine.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection >
Electronic Leak Detection > Page 7873
5. Open the high-pressure service valve.
6. Open the special tool valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the special tool to equalize
with the suction side of the refrigerant system.
8. NOTE: Close the valves on the special tool while the A/C compressor is operating.
Close the valves on the special tool.
9. NOTE: Leave all valves on the special tool closed when not in use.
Disconnect the high-pressure and low-pressure service valves and remove the special tool from
the vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure
Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure
AIR CONDITIONING (A/C) SYSTEM RECOVERY
Special Tool(s)
SPECIAL TOOL(S)
Refrigerant System Recovery
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7876
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant.
2. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set.
Connect an R-134a A/C service center to the low and high-pressure service gauge port valves.
3. Recover the refrigerant from the system following the operating instructions provided by the
equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system
refrigerant, close the service center inlet valve (if 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 vacuum
does not decrease, disconnect the refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains
stable for two minutes. 7. Carry out the required repairs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7877
Refrigerant: Service and Repair Evacuation and Charging
AIR CONDITIONING (A/C) SYSTEM EVACUATION AND CHARGING
Special Tool(s)
SPECIAL TOOL(S)
Refrigerant System Evacuation
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7878
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
1. Connect an R134a service center to the low- and high-pressure service gauge port valves. 2.
Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum
and as close to 101.1 kPa (30 in-Hg) as
possible. Continue to operate the vacuum pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that
the system vacuum is held. If vacuum is not held
for five minutes, leak test the system, service the leak, and evacuate the system again.
Refrigerant System Charging
NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available,
refrigerant system recovery, evacuation, and charging may be accomplished using a separate
recovery station, vacuum pump, charging cylinder, and manifold gauge set.
1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the
system. 2. Charge the system with the specified amounts of refrigerant oil and refrigerant. 3. When
no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation.
Adjust the blower motor speed to the
maximum and allow the remaining refrigerant to be drawn into the system. Continue to add
refrigerant into the system until the specified weight of R-134a has been added. Close the charging
cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the
low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7879
Refrigerant: Service and Repair Identifying Refrigerants
REFRIGERANT IDENTIFICATION TESTING
Delux A/C Refrigerant Analyzer
SPECIAL TOOL(S)
1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior
to recovering or charging the refrigerant system.
Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample
for testing.
2. The diagnostic tool will display one of the following:
- If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" light emitting
diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will
be displayed on the digital display.
- If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and
a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12,
R-22, and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user
of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will also
be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is
98% or greater. The diagnostic tool eliminates the
effect of air when determining the refrigerant sample content because air is not considered a
contaminant, although air can affect A/C system performance. when the diagnostic tool has
determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air
concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air
purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
5. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
or R-12 recovery/recycling equipment.
Recover any contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Refrigerant Discharging and Recovery Procedure > Page 7880
Refrigerant: Service and Repair Handling of Contaminated Refrigerants
CONTAMINATED REFRIGERANT HANDLING
1. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your
recovery/recycling equipment.
Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to
other vehicles.
- If this equipment is not available, contact an A/C service facility in your area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customer's initial concern.
3. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured
for correct oil system matching.
The suction accumulator/drier cannot be cleaned. A new suction accumulator/drier must be
installed.
Remove the suction accumulator/drier.
4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction
accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8.
Dispose of contaminated refrigerant according to all federal, state and local regulations.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Page 7881
Refrigerant: Tools and Equipment
Refrigerent Leak Detector
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Page 7882
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair >
Page 7883
Delux A/C Refrigerant Analyzer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Control Solenoid Valve > Component Information >
Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Capacity without auxiliary climate control.............................................................................................
.............................................................266 ml (9 oz)
Capacity with auxiliary climate control..................................................................................................
...........................................................384 ml (13 oz)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7891
Refrigerant Oil: Fluid Type Specifications
Refrigerant Oil
............................................................................................................................................. PAG
Refrigerant Compressor Oil, YN-12-C
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
7892
Refrigerant Oil: Service Precautions
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed, some of the 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
7893
Refrigerant Oil: Service and Repair
REFRIGERANT OIL ADDING
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system are
removed, some of the 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. NOTE: Service A/C compressors are shipped without compressor oil.
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 Refrigerant Compressor Oil (R-134a
Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 Refrigerant Compressor Oil (R-134a
Systems) F7AZ-19589-DA (Motorcraft YN-12-C) 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 Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B
into the new A/C compressor.
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 Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA
(Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft
YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction
accumulator/drier inlet tube.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
7894
4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft
YN-12-C) 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 Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations
View 151-13
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7899
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7900
High Pressure Sensor / Switch: Description and Operation
HIGH PRESSURE CUTOFF SWITCH
The high pressure cutoff switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures. The high pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure
side of the compressor manifold and tube assembly.
- A valve depressor, located inside the threaded end of the high pressure cutoff switch, presses on
the Schrader valve stem.
- This allows the high pressure cutoff switch to monitor the A/C compressor discharge pressure.
- When the A/C compressor discharge pressure rises, the switch contacts open, disengaging the
A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor.
- It is not necessary to discharge the refrigerant system to remove the high pressure cutoff switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 7906
View 151-11
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay > Page 7909
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Blower Motor Relay > Page 7910
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay
Blower Motor Relay: Testing and Inspection High Speed Fan Control Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 7913
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 7914
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 7915
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 7916
Blower Motor Relay: Testing and Inspection Auxiliary A/C Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > High Speed Fan Control Relay > Page 7917
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7921
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7922
Compressor Clutch Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7923
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module
Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 7929
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Electronic Automatic Temperature Control (EATC) Module > Page 7930
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Page 7931
Control Module HVAC: Description and Operation
DATC MODULE
The DATC module: is located in the instrument panel.
- has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed
and diagnostic trouble codes (DTCs).
- utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble
codes (DTCs). These DTCs direct the technician to the inoperative component.
BLOWER MOTOR SPEED CONTROL
The blower speed control: is located on the heater core and evaporator core housing near the blower motor.
- converts low power signals from the DATC module to a high current, variable ground feed for the
blower motor.
- varies the blower motor speed and is controlled by the DATC module software.
- has a delay function to provide a gradual increase or decrease in blower motor speed under all
conditions.
- controls the integral high blower speed relay which is engaged when maximum fan speed is
selected.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Page 7932
Control Module HVAC: Service and Repair
BLOWER MOTOR SPEED CONTROL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7937
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7938
Ambient Temperature Sensor / Switch HVAC: Description and Operation
AMBIENT AIR TEMPERATURE SENSOR
The ambient air temperature sensor and bracket: is located in front of the condenser core.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the DATC module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7939
Ambient Temperature Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7940
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
REMOVAL
1. Remove the radiator grille.
2. Remove the components in the order listed in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Description and Operation
Blower Motor Switch: Description and Operation
BLOWER MOTOR SWITCH
The blower motor switch controls blower motor speed by adding or bypassing resistors in the
blower motor switch resistor in all function selector switch positions except OFF.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7947
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7948
Cabin Temperature Sensor / Switch: Description and Operation
IN-VEHICLE TEMPERATURE SENSOR
The in-vehicle temperature sensor operates in the following manner: A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the heater core
and evaporator core housing and the in-vehicle temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the heater core and
evaporator core housing air stream to create a suction in the in-vehicle temperature sensor.
- The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7949
In-Vehicle Temperature Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7950
Cabin Temperature Sensor / Switch: Service and Repair
IN-VEHICLE TEMPERATURE SENSOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Instrument Cluster Finish Panel Removal Note
1. Remove the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-13
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7955
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7956
High Pressure Sensor / Switch: Description and Operation
HIGH PRESSURE CUTOFF SWITCH
The high pressure cutoff switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures. The high pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure
side of the compressor manifold and tube assembly.
- A valve depressor, located inside the threaded end of the high pressure cutoff switch, presses on
the Schrader valve stem.
- This allows the high pressure cutoff switch to monitor the A/C compressor discharge pressure.
- When the A/C compressor discharge pressure rises, the switch contacts open, disengaging the
A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor.
- It is not necessary to discharge the refrigerant system to remove the high pressure cutoff switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations
Solar Sensor: Locations
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 7960
View 151-31
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 7961
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 7962
Solar Sensor: Description and Operation
SOLAR RADIATION SENSOR
The solar radiation sensor supplies information to the DATC module indicating LH side and RH
side sunload.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Vacuum Sensor / Switch HVAC
> Component Information > Description and Operation
Vacuum Sensor / Switch HVAC: Description and Operation
HEATER CONTROL VALVE VACUUM SWITCH
The heater control valve vacuum switch to control operation of the heater control valve. The heater
control valve vacuum switch: is mounted on the RH side of the heater core and evaporator core housing just below the defrost
door vacuum control motor.
- is actuated by an arm attached to the temperature blend door RH pivot shaft.
- applies vacuum to the heater control valve when the temperature blend door is in the full COOL
position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Service Port HVAC: Locations
Clutch Cycling Orifice Tube Type Refrigerant System, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page
7969
Clutch Cycling Orifice Tube Type Refrigerant System, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations
Solar Sensor: Locations
View 151-30
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 7973
View 151-31
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 7974
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 7975
Solar Sensor: Description and Operation
SOLAR RADIATION SENSOR
The solar radiation sensor supplies information to the DATC module indicating LH side and RH
side sunload.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions
Vacuum Harness HVAC: Service Precautions
WARNING: Read the warning information on the product label to prevent possible personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Page 7979
Vacuum Harness HVAC: Service and Repair
VACUUM HOSE REPAIR - MINI-TUBE
Vacuum Pump Kit
SPECIAL TOOL(S)
1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of
standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 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. WARNING: Read the warning information on the product label to prevent possible personal
injury.
Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone
(MEK). This solvent will seal the mini-tube in the vacuum hose.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the
standard 1/8 inch repair vacuum hose section. 6. Shake the repair joint after assembly to make
sure the solvent is dispersed and the vacuum line is not plugged.
7. Test the system for a vacuum leak in the repair area.
- Use the Vacuum Pump or equivalent.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Page 7980
Vacuum Pump Kit
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service
and Repair
Vacuum Reservoir HVAC: Service and Repair
VACUUM RESERVOIR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Sensor / Switch HVAC > Component Information >
Description and Operation
Vacuum Sensor / Switch HVAC: Description and Operation
HEATER CONTROL VALVE VACUUM SWITCH
The heater control valve vacuum switch to control operation of the heater control valve. The heater
control valve vacuum switch: is mounted on the RH side of the heater core and evaporator core housing just below the defrost
door vacuum control motor.
- is actuated by an arm attached to the temperature blend door RH pivot shaft.
- applies vacuum to the heater control valve when the temperature blend door is in the full COOL
position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Description and Operation
Vacuum Solenoid Valve HVAC: Description and Operation
AUTOMATIC TEMPERATURE CONTROL (ATC) SOLENOID AND MANIFOLD
The ATC solenoid and manifold: is located on the heater core and evaporator core housing near the blower motor.
- uses solenoid-type valves to distributes vacuum to the vacuum control motors and heater control
valve based on the settings of the DATC module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Description and Operation > Page 7990
ATC Solenoid And Manifold
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment
Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After
A Supplemental Restraint System (SRS) Deployment
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools
are not removed, the supplemental restraint system (SRS) device may not deploy in a crash.
Failure to follow this instruction may result in serious personal injury or death in a crash and
possibly violate vehicle safety standards.
NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system
diagnostic tools (if required) must be removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in
various combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle
repairs affecting the SRS and safety belt system.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices are deployed and/or the restraints control
module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the
vehicle's SRS is to include the removal of all deployed devices and the installation of new
deployable devices, the removal and installation of new impact sensors, and the removal and
installation of a new RCM. DTCs must cleared from all required modules after repairs are carried
out.
Vehicles with occupant classification sensor (OCS) system
2. NOTE: After installation of new occupant classification sensor (OCS) system components carry
out the OCS System Reset procedure as
instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system
removal and installation procedure.
When a vehicle has been involved in a collision and the occupant classification system module
(OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following
procedures for the specified system:
- For rail type OCS system, inspect the passenger side floorpan for damage and repair as
necessary. Install new OCS system rails.
- For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and
repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be
cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset.
Do not install a new OCSM unless DTC B1231 cannot be cleared.
- NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The
DTC B1231 is stored only by the RCM.
For bladder type OCS system, inspect for damage and repair as necessary. If installation of an
OCS system component is required, an OCS system service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting
hardware as needed.
4. When the driver air bag module has deployed, a new clockspring must be installed.
5. New driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is
involved in a collision that results in deployment of the driver and/or front passenger safety belt
pretensioners. For additional information, refer to Safety Belt System.
6. Inspect the entire vehicle for damage, including the following components:
Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting
points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat
mounting points Safety belts, safety belt buckles and safety belt retractors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7996
SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 7997
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
SAFETY BELT PROCEDURE AFTER A COLLISION
1. 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 correctly. Belt assemblies not in use
during a collision should also be inspected and replaced if either damage or improper 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. See:
Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service Precautions > Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service Precautions > Technician Safety Information > Page 8003
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8006
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8007
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8008
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8009
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8010
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8011
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8012
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8013
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8014
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8015
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8016
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8017
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8018
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8019
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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
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> Service and Repair > Air Bag Disarming and Arming > Page 8020
10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8021
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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> Service and Repair > Air Bag Disarming and Arming > Page 8022
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8023
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
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- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
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17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
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Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
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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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
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3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
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7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
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11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
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17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
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All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
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2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
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> Service and Repair > Air Bag Disarming and Arming > Page 8036
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
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> Service and Repair > Air Bag Disarming and Arming > Page 8037
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
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> Service and Repair > Air Bag Disarming and Arming > Page 8038
13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
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All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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> Service and Repair > Air Bag Disarming and Arming > Page 8040
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
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> Service and Repair > Air Bag Disarming and Arming > Page 8041
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
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> Service and Repair > Air Bag Disarming and Arming > Page 8042
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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.
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> Service and Repair > Page 8043
Special Tool(s)
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations
View 151-32
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8047
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service Precautions
> Customer Safety Information
Air Bag: Customer Safety Information
WARNING: Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper
trim panels and attaching hardware must be replaced along with any other damaged components
and hardware. Failure to do so can result in personal injury in the event of a safety canopy
deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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> Customer Safety Information > Page 8050
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 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 or the safety canopy 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.
- The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior
to road use. Failure to remove could result in injury and possible violation of vehicle safety
standards.
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of personal injury from an accidental deployment, always carry or place a live
safety canopy module with the safety canopy and tear seam pointed away from your body. Failure
to do so can result in personal injury in the event of a safety canopy module deployment.
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment.
- Vehicles equipped with safety canopy modules require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety
canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets
each B and C-pillar trim panel. Failure to do so can result in personal injury in the event of a safety
canopy module deployment.
- Before installing a safety canopy module, inspect the roofline for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be replaced and any foreign objects removed. Failure to do so may result in
personal injury in the event of a safety canopy deployment.
- Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has
separated and the canopy material has been exposed, a new safety canopy module must be
installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can
result in personal injury in the event of a safety canopy module deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
- Never probe the connector on the safety canopy module. Doing so can result in safety canopy
deployment which can result in personal injury.
- To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety
canopy module. Failure to follow these instructions can result in personal injury in the event of a
safety canopy module deployment.
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> Customer Safety Information > Page 8051
Air Bag: Vehicle Damage Warnings
CAUTION:
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
- Do not handle the passenger air bag module by grabbing the edges of the deployment door.
- The passenger air bag module nuts must be torqued in the sequence shown.
- The safety canopy retainers must always be tightened starting in the middle and work out from
there.
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> Page 8052
Air Bag: Description and Operation
SAFETY CANOPY MODULE
WARNING: Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper
trim panels and attaching hardware must be replaced along with any other damaged components
and hardware. Failure to do so can result in personal injury in the event of a safety canopy
deployment.
The side air curtain module or safety canopy:
- is installed as an assembly.
- is mounted above the headliner.
- attaches from the A-pillar frame to the C-pillar frame.
DRIVER AIR BAG MODULE
The driver air bag module: is installed new as an assembly.
- is mounted in the center of the steering wheel.
PASSENGER AIR BAG MODULE
The passenger air bag module: is installed new as an assembly.
- is mounted in the passenger side of the instrument panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module
Air Bag: Service and Repair Driver Air Bag Module
DRIVER AIR BAG MODULE
Special Tool(s)
SPECIAL 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.
- 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.
- 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:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8055
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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
NOTE: Within the Supplemental Restraint System (SRS) Deactivation and Reactivation procedure
the driver air bag module is removed and restraint system diagnostic tools are attached at the
appropriate locations.
Deactivate the supplemental restraint system (SRS).
INSTALLATION
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the removal procedure.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8056
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Install the components in the order indicated in the illustration and table.
2. Connect the battery ground cable.
3. 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.
With the restraint system diagnostic tools still installed at the remaining deployable devices, prove
out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and
Repair/Prove Out Procedure
4. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8057
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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Item 3: Driver Air Bag Module Connectors Installation Note
1. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module and connect the
electrical connectors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8058
Air Bag: Service and Repair Passenger Air Bag Module
PASSENGER AIR BAG MODULE
SPECIAL 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.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged deployment doors must be replaced, not repainted.
- 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:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. 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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8059
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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. NOTE: Within the Supplemental Restraint System (SRS) Deactivation and Reactivation
procedure the passenger air bag module is disconnected
and a restraint system diagnostic tool is attached at the appropriate location.
Remove the components in the order indicated in the illustration and table.
Item 2: Passenger Air Bag Module Removal Note
1. 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,
releasing the clips at the top and remove the passenger air bag module from the instrument panel.
INSTALLATION
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and
notes at the beginning of the removal procedure.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8060
1. CAUTION: The passenger air bag module nuts must be torqued in the sequence shown.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Install the components in the order indicated in the illustration and table.
2. Close the glove compartment. 3. Connect the battery ground cable.
4. 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.
With the restraint system diagnostic tools still installed at the remaining deployable devices, prove
out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and
Repair/Prove Out Procedure
5. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
7. Connect the battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8061
8. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Item 1: Retaining Clip Installation Note
1. Make sure the retaining clips are in place before positioning the passenger air bag module to the
instrument panel.
Item 5: Passenger Air Bag Module Connector Installation Note
1. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8062
Air Bag: Service and Repair Safety Canopy Module
Removal and Installation
SAFETY CANOPY MODULE
Special Tool(s)
SPECIAL 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.
- To reduce the risk of personal injury from an accidental deployment, always carry or place a live
safety canopy module with the safety canopy and tear seam pointed away from your body. Failure
to do so can result in personal injury in the event of a safety canopy module deployment.
- After deployment, the surface of the safety canopy 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 connector on the safety canopy module. Doing so can result in safety canopy
deployment which can result in personal injury.
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment.
- Vehicles equipped with safety canopy modules require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety
canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets
each B and C-pillar trim panel. Failure to do so can result in personal injury in the event of a safety
canopy module deployment.
- Before installing a safety canopy module, inspect the roofline for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be replaced and any foreign objects removed. Failure to do so may result in
personal injury in the event of a safety canopy deployment.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8063
- Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has
separated and the canopy material has been exposed, a new safety canopy module must be
installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can
result in personal injury in the event of a safety canopy module deployment.
- To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety
canopy module. Failure to follow these instructions can result in personal injury in the event of a
safety canopy module deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
NOTE:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. WARNING: Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
Remove the headliner.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8064
Part 1
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8065
Part 2
4. Remove the components in the order indicated in the illustration and table.
Item 4: C-Pillar Tether Anchor Assembly Removal Note
1. Slide the tether anchor assembly up and out to disengage it from the C-pillar.
Item 11: A-Pillar Tether Pin-Type Retainer Removal Note
1. If reusing the same safety canopy, separate the tether from the pin-type retainer. If a new safety
canopy is being installed, remove the tether with
the pin-type retainer.
Item 12: Rear Ramp Removal Note
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> Driver Air Bag Module > Page 8066
1. Push the retainers together and separate the rear ramp from the sheet metal.
Item 13: Safety Canopy Removal Note
1. Remove the safety canopy.
1 Push the safety canopy cover in, releasing it from the front ramp lower retainers and rotate the
bottom of the safety canopy up and out of the ramp.
2 Separate the safety canopy from the front ramp upper retainers.
3 Remove the safety canopy.
Item 14: Front Ramp Removal Note
1. Push the retainers together and separate the front ramp from the sheet metal.
INSTALLATION
WARNING:
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the removal procedure.
- Before installing a safety canopy module, inspect the roofline for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be replaced and any foreign objects removed. Failure to do so may result in
personal injury in the event of a safety canopy deployment.
- Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has
separated and the canopy material has been exposed, a new safety canopy module must be
installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can
result in personal injury in the event of a safety canopy module deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
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> Driver Air Bag Module > Page 8067
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
For vehicles receiving the same safety canopy, position the safety canopy back into the rear ramp.
1
Position the ramp upper retainers around the safety canopy, making sure the retainers are in the
safety canopy cover locator cutouts.
2 The safety canopy cover must be located behind the ramp tabs.
2. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the
installation portion of this procedure.
With the safety canopy module positioned in the vehicle as shown, angle the rear of the safety
canopy module toward the sheet metal. Insert the deployment canister into the sheet metal
opening.
3. Push in on the front and rear ramps engaging the ramp retainers to the sheet metal. An audible
click should be heard, indicating that the retainers
have engaged into the sheet metal.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8068
Part 1
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> Driver Air Bag Module > Page 8069
Part 2
4. CAUTION: The safety canopy retainers must always be tightened starting in the middle and work
out from there.
Install the components in the order indicated in the illustration and table.
5. Connect the battery ground cable. 6. With the restraint system diagnostic tools still installed at
the remaining deployable devices, prove out the supplemental restraint system (SRS).
See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
7. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
8. WARNING: Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
Install the headliner.
9. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
10. Connect the battery ground cable.
11. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 8070
Item 6: A-Pillar Tether Pin-Type Retainer Installation Note
1. If reusing the same safety canopy, route the tether through the pin-type retainer. If a new safety
canopy is being installed, install the tether and
pin-type retainer to the A-pillar.
Item 10: C-Pillar Tether Anchor Assembly Installation Note
1. Engage the rear tether anchor assembly hook to the C-pillar sheet metal.
Item 14: Safety Canopy Connector Installation Note
1. Remove the restraint system diagnostic tool from the safety canopy electrical connector.
Rivet Nut Replacement
RIVET NUT REPLACEMENT
CAUTION: If the safety canopy module has deployed, the tether cord rivet nut must be inspected
and replaced if damaged before installing a new safety canopy.
NOTE:
- A typical rivet nut replacement is shown that is similar for all vehicles.
- The left-hand drive driver side is shown, others are similar.
1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
2. Remove the A-pillar trim panel.
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> Driver Air Bag Module > Page 8071
3. Remove the bolt and bracket for the tether cord from the A-pillar. 4. Position and secure the side
air curtain tether cord and bracket assembly out of the way.
5. Using the appropriate service tool, sand the rivet nut shoulder until the shoulder surface is
removed. 6. Punch the remaining portion of the rivet nut through the rivet nut hole.
7. NOTE: Use only Ford Motor Company factory-authorized replacement parts for rivet nut repair
procedure.
Obtain the correct square shank rivet nut for the vehicle application from the Ford Master Parts
Catalog, and insert it into the rivet nut hole.
8. Using a suitable rivet nut installing tool, install the rivet nut. 9. Position the A-pillar tether cord.
Install the bolt. See the appropriate component removal and installation procedure or Specifications
for the
correct torque specification.
10. NOTE: The tether cord must be positioned correctly in place before installing the A-pillar trim
panel.
Install the A-pillar trim panel.
11. WARNING: To reduce the risk of serious injury, read and follow all warnings, cautions, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
12. WARNING: The restraint system diagnostic tools are 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Page 8072
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8078
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8079
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8080
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8081
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8082
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8083
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 8084
Air Bag Control Module: Locations
View 151-21
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Technical Service Bulletins > Page 8085
View 151-24
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 8086
Air Bag Control Module: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 8087
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Customer Safety Information
Air Bag Control Module: Customer Safety Information
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) has been involved in a collision in which the center tunnel
area has been damaged, inspect the mounting and bracket for deformation. If damaged, 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.
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Customer Safety Information > Page 8090
Air Bag Control Module: Technician Safety Information
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for proper air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be 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.
- 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 SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag restraints control module (RCM) retaining nuts is critical for
correct system operation.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Customer Safety Information > Page 8091
Air Bag Control Module: Vehicle Damage Warnings
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
can result.
- Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical
connections and damage components.
- Installing a J-nut in place of a weld nut is not a recommended repair.
- Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed
to get the connector into position on the RCM before using the lever to fully seat the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Page 8092
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) has been involved in a collision in which the center tunnel
area has been damaged, inspect the mounting and bracket for deformation. If damaged, 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.
N0TE: when installing a new restraints control module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed, erroneous DTCs will result.
The restraints control module carries out the following functions: deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioners to remove slack from the safety belt.
- monitors the 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 instrument cluster module to activate a chime if the air bag indicator is not available
and another SRS fault exists.
The RCM monitors the SRS for possible facts. If a fault is detected while the ignition switch is in the
ON 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 a 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 instrument cluster module 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 lost or damaged during impact. The backup
power supply will deplete its stored energy approximately one minute after the battery ground cable
is disconnected.
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Page 8093
Air Bag Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Air Bag Systems; Testing and Inspection.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > General Procedure
Air Bag Control Module: Service and Repair General Procedure
Missing Weld Nut
WELD NUT REPAIR - MISSING WELD NUT
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
NOTE: C-pillar repair shown, others similar.
1. Remove the component from where the weld nut is to be repaired.
2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face
will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32
in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding
screw (self-tapping).
5. Set up for the positioning of the weld nut.
1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent
access hole.
2 Position a weld nut, shoulder end up, onto the wire.
3 Position a flat washer onto the wire and secure it so it cannot be pulled off.
6. Plug weld the weld nut into position.
1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the welding wire through and stop against the sheet metal.
2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal.
3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled
previously.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > General Procedure > Page 8096
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the
previously obtained screw.
10. Tighten the attaching screws to specification.
Stripped Weld Nut
WELD NUT REPAIR - STRIPPED WELD NUT
1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and
surrounding area for repair.
- If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn,
then a threaded insert will have to be installed. Follow the instructions with the thread insert repair
kit.
3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit.
Then tap, using an 8 mm by 1.25 bit.
- Do not oversize a 6 mm weld nut by more than 8 mm.
4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit.
Then tap, using a 10 mm by 1.50 bit.
- Do not oversize an 8 mm weld nut by more than 10 mm.
5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7.
Tighten the attaching screws to specification.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > General Procedure > Page 8097
Air Bag Control Module: Service and Repair Removal and Installation
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for proper air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be 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.
- 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 SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag restraints control module (RCM) retaining nuts is critical for
correct system operation.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- 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. 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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > General Procedure > Page 8098
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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the floor console.
4. Remove the components in the order indicated in the illustration and table.
Item 1: Large Electrical Connector Removal Note
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > General Procedure > Page 8099
1. Disconnect the large restraints control module (RCM) electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it
stops.
2 Pull out and disconnect the RCM electrical connector.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Item 1: Large Electrical Connector Installation Note
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > General Procedure > Page 8100
1. Make sure the connector position assurance lever is in the full release position before attempting
to connect the connector.
2. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
NOTE: The RCM has been removed for clarity.
Position the large RCM electrical connector into the RCM.
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Service and Repair > General Procedure > Page 8101
3. NOTE: The RCM has been removed for clarity.
Connect the large RCM electrical connector. Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Service and Repair > Page 8102
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
Precautions > Technician Safety Information
Air Bag Resistor: 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.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- Restraint system diagnostic tools are for service only. Tools must be removed prior to operating
the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury
and possible violation of vehicle safety standards.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
Precautions > Technician Safety Information > Page 8108
Air Bag Resistor: Vehicle Damage Warnings
CAUTION: Do not deactivate the side air curtain module or safety canopy module circuit by
removing the bridge resistor from the electrical connector.
If the side air curtain or safety canopy bridge resistor is removed, an open circuit fault will be
generated by the restraints control module (RCM).
If a restraint system diagnostic tool is installed at the side air curtain or safety canopy electrical
connector, a low resistance fault will be generated.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
Precautions > Page 8109
Air Bag Resistor: Description and Operation
SAFETY CANOPY BRIDGE RESISTOR
CAUTION: Do not deactivate the side air curtain module or safety canopy module circuit by
removing the bridge resistor from the electrical connector.
If the side air curtain or safety canopy bridge resistor is removed, an open circuit fault will be
generated by the restraints control module (RCM).
If a restraint system diagnostic tool is installed at the side air curtain or safety canopy electrical
connector, a low resistance fault will be generated.
The safety canopy bridge resistor:
- is equipped on vehicles without safety canopy modules.
- must not be removed during deactivation.
- is located at the LH C-pillar.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
Precautions > Page 8110
Air Bag Resistor: Service and Repair
SAFETY CANOPY BRIDGE RESISTOR
Special Tool(s)
SPECIAL 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.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
Precautions > Page 8111
3. Remove the LH C-pillar trim panel.
4. Remove the components in the order indicated in the illustration and table.
Item 1: Safety Canopy Bridge Resistor Removal Note
1. Remove the safety canopy bridge resistor with the pin-type retainer.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior
to operating the vehicle over the road.
Failure to remove restraint system diagnostic tools could result in injury and possible violation of
vehicle safety standards.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
8. Check the active restraint system for correct operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service
Precautions > Page 8112
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams
Clockspring Assembly / Spiral Cable: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Technician Safety Information
Clockspring Assembly / Spiral Cable: 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 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.
- The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior
to road use. Failure to remove could result in injury and possible violation of vehicle safety
standards.
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- Incorrect centralization may result in premature component failure. If in doubt when centralizing
the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in
personal injury.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Technician Safety Information > Page 8118
Clockspring Assembly / Spiral Cable: Vehicle Damage Warnings
CAUTION:
- Do not use a prying device to detach the shift lever boot or damage to the steering column
shrouds can result.
- Make sure the road wheels are in the straight-ahead position.
- Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be
broken from its internal connection.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8119
Clockspring Assembly / Spiral Cable: Description and Operation
CLOCKSPRING
The clockspring:
- is mounted on the steering column, behind the steering wheel.
- continuously transfers electrical signals from the driver air bag module to the restraints control
module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8120
Clockspring Assembly / Spiral Cable: Service and Repair
CLOCKSPRING
Special Tool(s), Part 1
Diagnostic Tool, Restraint System
SPECIAL 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.
- 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.
- 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:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8121
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Make sure the road wheels are in the straight-ahead position.
4. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the steering
wheel removal and installation procedure.
Remove the steering wheel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8122
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8123
Part 2
6. NOTE: If the clockspring is to be reinstalled, do not allow the clockspring to turn from its removal
position.
Remove the components in the order indicated in the illustration and table.
7. Connect the battery ground cable. 8. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
9. Disconnect the battery ground cable and wait at least one minute.
Item 3: Gear Shift Lever Boot Removal Note
1. CAUTION: Do not use a prying device to detach the shift lever boot or damage to the steering
column shrouds can result.
Detach the gear selector boot from the shrouds.
Item 6: Upper Steering Column Shroud Removal Note
1. Remove e upper steering column shroud.
1 Lift where shown to release the retaining clips, and rotate the upper steering column trim panel
out of the instrument cluster finish panel.
2 Remove the upper steering column shroud hard shell.
Item 7: Tape Removal Note
1. If installing the same clockspring, apply two strips of masking tape across the clockspring to
prevent accidental rotation when the clockspring is
removed.
Item 9: Multi-function Switch Removal Note
1. While releasing the retaining tab at the top of the multi-function switch, slide the multi-function
switch up and out of the way.
Item 12: Clockspring Connectors Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8124
1. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring
electrical connector.
Item 14: Clockspring Mounting Bracket Removal Note
1. Inspect the clockspring mounting bracket for damage and remove as necessary.
INSTALLATION
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and
notes at the beginning of the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8125
Part 1
Part 2
1. NOTE: Make sure the negative battery cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8126
Install the components in the order indicated in the illustration and table.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the steering
wheel removal and installation procedure.
Install the steering wheel. Do not install the driver air bag module at this time.
3. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column. 4. Connect the battery ground cable. 5. With the restraint system diagnostic
tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See:
Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
6. Disconnect the battery ground cable and wait at least one minute.
7. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
9. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Item 3: Clockspring Connectors Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8127
1. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring
electrical connector.
Item 4: Clockspring Installation Note
1. WARNING: Incorrect centralization may result in premature component failure. If in doubt when
centralizing the clockspring, repeat
the centralizing procedure. Failure to follow this instruction may result in personal injury.
CAUTION: Make sure the road wheels are in the straight-ahead position.
If the vehicle's clockspring has rotated out of center, follow these steps to center the clockspring.
1 Hold the clockspring outer housing stationary.
2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and
can be broken from its internal connection.
While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and
for a slight resistance. Stop turning at this point.
3 Turn the clockspring clockwise approximately three turns. This is the center point of the
clockspring. Do not allow the rotor to turn from this position.
2. NOTE: Slight turning of the clockspring rotor is allowable for alignment purposes to the steering
column.
Install the clockspring onto the steering column. 1
With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring
onto the steering column.
2 Install the bolts.
Item 6: Retaining Pin Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8128
1. For vehicles receiving a new clockspring, remove the retaining pin.
Item 7: Tape Installation Note
1. For vehicles reusing the clockspring that was removed, remove the tape.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Service Precautions > Page 8129
Clockspring Assembly / Spiral Cable: Tools and Equipment
Special Tool(s), Part 1
Special Tool(s), Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Front Impact Severity Sensor
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Front Impact Severity Sensor > Page 8134
View 151-60
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Front Impact Severity Sensor > Page 8135
View 151-52
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Front Impact Severity Sensor > Page 8136
View 151-40
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Front Impact Severity Sensor > Page 8137
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Front Impact Severity Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Front Impact Severity Sensor > Page 8140
Impact Sensor: Diagrams Side Impact Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Front Impact Severity Sensor > Page 8141
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Front Impact Severity Sensor > Page 8142
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Front Impact Severity Sensor > Page 8143
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information > Page 8146
Impact Sensor: Technician Safety Information
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 reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- The tightening torque of the air bag front impact severity sensor retaining bolts is critical for
correct system operation.
- 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.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Customer Safety Information > Page 8147
Impact Sensor: Vehicle Damage Warnings
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service
Precautions > Page 8148
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
For these vehicles, the SRS uses up to five satellite sensors in addition to the RCM. The RCM is
mounted to the center tunnel beneath the console. All vehicles will have a front impact severity
sensor and it is located in the front-center of the vehicle, mounted under the lower radiator support.
If the vehicle is equipped with safety canopies, there are four additional side impact sensors. The
four additional sensors are located at the base of each B-pillar and C-pillar. The LH and RH C-pillar
mounted side impact sensors are not interchangeable. Mounting orientation is critical for correct
operation of all impact and rollover sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation
Impact Sensor: Service and Repair Removal and Installation
Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
Special Tool(s)
SPECIAL TOOL(S)
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.
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. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8151
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolts is
critical for correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation
portion of this procedure.
- Make sure the lower radiator support and front impact severity sensor bracket mating surfaces
are clean and debris free.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8152
With all the restraint system diagnostic tools removed prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Item 3: Front Impact Severity Sensor Installation Note
1. Align the locator tab of the front impact severity sensor mounting bracket to the opening in the
lower radiator support sheet metal.
First Row, B-Pillar
SIDE IMPACT SENSOR - FIRST ROW, B-PILLAR
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped
with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or
any other damaged supplemental restraint system (SRS) components whether or not the air bag is
deployed.
NOTE:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8153
- 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.
- The driver side is shown, the passenger side is similar.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the B-pillar trim panel.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. WARNING: The tightening torque of the air bag side impact sensor retaining bolt is critical for
correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8154
To install, reverse the removal procedure
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
8. Check the active restraint system for correct operation.
Item 3: Side Impact Sensor Installation Note
1. Make sure the bolt, washer and clip are in place on the side impact sensor before installing it to
the vehicle.
2. Align the locator pegs to the openings in the B-pillar sheet metal.
Second Row, C-Pillar
SIDE IMPACT SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8155
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped
with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or
any other damaged supplemental restraint system (SRS) components whether or not the air bag is
deployed.
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.
- The RH side is shown, the LH side is similar.
- The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Removal and Installation > Page 8156
Part 1
Part 2
3. Remove the components in the order indicated in the illustration and table.
Item 4: Quarter Trim Panel Removal Note
1. Pull out on the rear quarter trim panel at the C-pillar to release the retaining clips and access the
C-pillar side impact sensor.
INSTALLATION
1. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for
correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s)
Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
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Repair > Removal and Installation > Page 8157
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
8. Check the active restraint system for correct operation.
Item 7: Side Impact Sensor Installation Note
1 Align the locator tab of the second row side impact sensor mounting bracket to the opening in the
C-pillar sheet metal.
Item 3: Safety Belt Anchor Installation Note
1. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Position the safety belt anchor and install the bolt.
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Impact Sensor: Service and Repair General Procedures
Missing Weld Nut
WELD NUT REPAIR - MISSING WELD NUT
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
NOTE: C-pillar repair shown, others similar.
1. Remove the component from where the weld nut is to be repaired.
2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face
will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32
in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding
screw (self-tapping).
5. Set up for the positioning of the weld nut.
1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent
access hole.
2 Position a weld nut, shoulder end up, onto the wire.
3 Position a flat washer onto the wire and secure it so it cannot be pulled off.
6. Plug weld the weld nut into position.
1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the welding wire through and stop against the sheet metal.
2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal.
3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled
previously.
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Repair > Removal and Installation > Page 8159
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the
previously obtained screw.
10. Tighten the attaching screws to specification.
Stripped Weld Nut
WELD NUT REPAIR - STRIPPED WELD NUT
1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and
surrounding area for repair.
- If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn,
then a threaded insert will have to be installed. Follow the instructions with the thread insert repair
kit.
3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit.
Then tap, using an 8 mm by 1.25 bit.
- Do not oversize a 6 mm weld nut by more than 8 mm.
4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit.
Then tap, using a 10 mm by 1.50 bit.
- Do not oversize an 8 mm weld nut by more than 10 mm.
5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7.
Tighten the attaching screws to specification.
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Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8167
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8168
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8169
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
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DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8171
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
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Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Component Information > Technical Service Bulletins > Page 8173
Air Bag Control Module: Locations
View 151-21
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Component Information > Technical Service Bulletins > Page 8174
View 151-24
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Component Information > Technical Service Bulletins > Page 8175
Air Bag Control Module: Diagrams
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Component Information > Technical Service Bulletins > Page 8176
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Customer Safety Information
Air Bag Control Module: Customer Safety Information
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) has been involved in a collision in which the center tunnel
area has been damaged, inspect the mounting and bracket for deformation. If damaged, 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.
- Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Customer Safety Information > Page 8179
Air Bag Control Module: Technician Safety Information
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for proper air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be 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.
- 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 SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag restraints control module (RCM) retaining nuts is critical for
correct system operation.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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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Component Information > Service Precautions > Customer Safety Information > Page 8180
Air Bag Control Module: Vehicle Damage Warnings
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
can result.
- Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical
connections and damage components.
- Installing a J-nut in place of a weld nut is not a recommended repair.
- Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed
to get the connector into position on the RCM before using the lever to fully seat the connector.
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Component Information > Service Precautions > Page 8181
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct system operation. If a vehicle equipped with an air bag
supplemental restraint system (SRS) has been involved in a collision in which the center tunnel
area has been damaged, inspect the mounting and bracket for deformation. If damaged, 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.
N0TE: when installing a new restraints control module (RCM), always make sure the correct RCM
is being installed. If an incorrect RCM is installed, erroneous DTCs will result.
The restraints control module carries out the following functions: deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioners to remove slack from the safety belt.
- monitors the 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 instrument cluster module to activate a chime if the air bag indicator is not available
and another SRS fault exists.
The RCM monitors the SRS for possible facts. If a fault is detected while the ignition switch is in the
ON 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 a 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 instrument cluster module 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 lost or damaged during impact. The backup
power supply will deplete its stored energy approximately one minute after the battery ground cable
is disconnected.
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Component Information > Service Precautions > Page 8182
Air Bag Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Air Bag Systems; Testing and Inspection.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure
Air Bag Control Module: Service and Repair General Procedure
Missing Weld Nut
WELD NUT REPAIR - MISSING WELD NUT
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
NOTE: C-pillar repair shown, others similar.
1. Remove the component from where the weld nut is to be repaired.
2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face
will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32
in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding
screw (self-tapping).
5. Set up for the positioning of the weld nut.
1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent
access hole.
2 Position a weld nut, shoulder end up, onto the wire.
3 Position a flat washer onto the wire and secure it so it cannot be pulled off.
6. Plug weld the weld nut into position.
1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the welding wire through and stop against the sheet metal.
2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal.
3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled
previously.
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Component Information > Service and Repair > General Procedure > Page 8185
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the
previously obtained screw.
10. Tighten the attaching screws to specification.
Stripped Weld Nut
WELD NUT REPAIR - STRIPPED WELD NUT
1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and
surrounding area for repair.
- If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn,
then a threaded insert will have to be installed. Follow the instructions with the thread insert repair
kit.
3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit.
Then tap, using an 8 mm by 1.25 bit.
- Do not oversize a 6 mm weld nut by more than 8 mm.
4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit.
Then tap, using a 10 mm by 1.50 bit.
- Do not oversize an 8 mm weld nut by more than 10 mm.
5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7.
Tighten the attaching screws to specification.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure > Page 8186
Air Bag Control Module: Service and Repair Removal and Installation
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for proper air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be 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.
- 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 SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag restraints control module (RCM) retaining nuts is critical for
correct system operation.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE:
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- 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. 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
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > General Procedure > Page 8187
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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the floor console.
4. Remove the components in the order indicated in the illustration and table.
Item 1: Large Electrical Connector Removal Note
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Component Information > Service and Repair > General Procedure > Page 8188
1. Disconnect the large restraints control module (RCM) electrical connector.
1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it
stops.
2 Pull out and disconnect the RCM electrical connector.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out
Procedure
Item 1: Large Electrical Connector Installation Note
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Component Information > Service and Repair > General Procedure > Page 8189
1. Make sure the connector position assurance lever is in the full release position before attempting
to connect the connector.
2. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
NOTE: The RCM has been removed for clarity.
Position the large RCM electrical connector into the RCM.
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
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Component Information > Service and Repair > General Procedure > Page 8190
3. NOTE: The RCM has been removed for clarity.
Connect the large RCM electrical connector. Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
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Component Information > Service and Repair > Page 8191
Special Tool(s)
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8196
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8197
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8198
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8199
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8200
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8201
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
8202
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions > Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions > Technician Safety Information > Page 8208
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
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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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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.
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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 8211
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
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Information > Service and Repair > Air Bag Disarming and Arming > Page 8212
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
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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 8213
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
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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 8214
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
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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 8215
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
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Information > Service and Repair > Air Bag Disarming and Arming > Page 8216
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
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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 8217
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
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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 8218
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8219
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8220
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8221
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
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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 8222
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8223
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
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10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
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4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
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10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
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12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
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17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
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Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
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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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
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7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
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11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
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17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
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All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
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2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
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6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
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9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
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13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
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All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
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Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
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Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
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Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Page 8248
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service Precautions
Child Seat Tether Attachment: Service Precautions
WARNING: The child safety seat tether anchor/bolt MUST be securely tightened to specification.
Otherwise, the child safety seat may not be correctly secured and the child could be injured if the
vehicle is involved in a collision or stops suddenly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service Precautions > Page 8253
Child Seat Tether Attachment: Description and Operation
CHILD SAFETY SEAT TETHER ANCHORS
WARNING: The child safety seat tether anchor/bolt MUST be securely tightened to specification.
Otherwise, the child safety seat may not be correctly secured and the child could be injured if the
vehicle is involved in a collision or stops suddenly.
The second row outboard child safety seat tether anchors for a five passenger vehicle are located
directly behind the seat, attached to the floor pan protruding from the carpet. Either of the tether
anchors for a five passenger vehicle located near the back hatch door can be used for the second
row center child safety seat tether anchor.
The three second row seats of a seven passenger vehicle have child safety seat tether anchors
that arc located directly behind the second row seats attached to the floor pan, protruding from the
carpet. The two third row child safety seat tether anchors are located directly behind the seat near
the back hatch door.
If the child safety seat tether anchors were in use during a collision, inspect and install new anchors
as necessary. Return the vehicle structure to its original production configuration.
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.
Lower Anchors and Tethers for Children (LATCH)
The lower anchors and tethers for children (LATCH) system is a standardized and uniform
attachment system for installing child safety seats in passenger vehicles. LATCH-equipped child
safety seats have two lower attachments that connect to the vehicle portion of the LATCH system.
The vehicle portion of the system consists of two attachment points (6mm wires) welded to the rear
seat cushion frame. The attachment points protrude from the beltline between the seat cushion and
seat backrest.
If a child safety seat was in use during a collision, inspect the vehicle portion of the system for
damage. If any of the attachment points (6mm wires) are damaged, install a new seat cushion
frame.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service Precautions > Page 8254
Child Seat Tether Attachment: Service and Repair
CHILD SAFETY SEAT TETHER ANCHOR
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.
NOTE: Sealant must be applied to the tether anchor bolts when installed.
1. To access the second row tether anchors, remove the third row seat cushion and position aside
the carpet. 2. To access the third row tether anchors, remove the rear hatch scuff plate.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service Precautions > Page 8255
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Restraints - Seat Belt Stop Button Service
Seat Belt: Technical Service Bulletins Restraints - Seat Belt Stop Button Service
TSB 05-3-10
02/21/05
SAFETY BELT WEB STOP BUTTON SERVICE
FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty
2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005
Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005
Escape Hybrid
LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey
ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding
down when not in use), a service kit is now available.
ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow
the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of
the appropriate model year Workshop Manual for additional information if needed.
NOTE
ONE KIT WILL REPAIR ONE SEAT BELT BUTTON.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
70611B09 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service
Precautions > Customer Safety Information
Seat Belt: Customer Safety Information
WARNING: Do not introduce slack into the safety belt system because the belt locks upon impact
where it is positioned. Use the shoulder safety belt on the outside shoulder only. Never wear the
shoulder safety belt under the arm. Never swing the shoulder safety belt around the neck over the
inside shoulder. Never use a single belt for more than one person. Make sure the lap portion of the
belt is fitted snugly and as low as possible around the hips, not the waist Failure to follow these
precautions could increase the chance and severity of injury in a collision.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service
Precautions > Customer Safety Information > Page 8262
Seat Belt: Technician Safety Information
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet)
away to ensure personal safety. Due to the loud report which occurs when the safety belt
pretensioner is deployed, hearing protection is required.
- Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that
moveable parts contact the support surface, as the forces of the deploying pretensioner can cause
it to ricochet and cause personal injury.
- Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep
fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an
accidental deployment.
- Do not bleach or re-dye the webbing, as the webbing may weaken.
- All safety belt assemblies including retractors, buckles, 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.
- After deployment, the air bag surface could 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.
- 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.
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 side impact sensors are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service
Precautions > Page 8263
Seat Belt: Description and Operation
FASTENING SAFETY BELTS
WARNING: Do not introduce slack into the safety belt system because the belt locks upon impact
where it is positioned. Use the shoulder safety belt on the outside shoulder only. Never wear the
shoulder safety belt under the arm. Never swing the shoulder safety belt around the neck over the
inside shoulder. Never use a single belt for more than one person. Make sure the lap portion of the
belt is fitted snugly and as low as possible around the hips, not the waist Failure to follow these
precautions could increase the chance and severity of injury in a collision.
Always follow the preceding safety precautions when fastening the safety belts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures
Seat Belt: Service and Repair General Procedures
Safety Belt Cleaning
SAFETY BELT CLEANING
1. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken.
Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery
or carpets. Follow the instructions provided with the soap.
Safety Belt With Anchor Plate Thread Damage
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. 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
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, a new nut or reinforcement should be installed. To install a
missing weld nut only, proceed to Step 3.
3. Obtain the correct M12 weld nut and a standard washer to perform the procedure. 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 hole. 8. Hold the weld nut securely in place. Use the MID 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 Tongue Rotated on Belt
SAFETY BELT TONGUE ROTATED ON BELT
1. Fold the safety belt as indicated.
2. Pull the safety belt tongue over the fold in the safety belt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8266
Deployed
SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED
1. WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses
when repairing an air bag equipped vehicle
and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never
probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag
deployment and could result in personal injury.
Dispose of the deployed safety belt pretensioner in the same manner as any other part to be
scrapped.
Inoperative
SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, INOPERATIVE
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep
fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an
accidental deployment.
NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have
been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and
safety belt retractor pretensioners must be treated the same as any inoperative live safety belt
buckle pretensioner or safety belt retractor pretensioner being returned.
1. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from
the vehicle. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt
retractor pretensioner to Ford Motor Company.
Scrapped Vehicle
SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, SCRAPPED VEHICLE
REMOTE DEPLOYMENT
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet)
away to ensure personal safety. Due to the loud report which occurs when the safety belt
pretensioner is deployed, hearing protection is required.
- Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that
moveable parts contact the support surface, as the forces of the deploying pretensioner can cause
it to ricochet and cause personal injury.
1. Remove the safety belt buckle pretensioner assembly from the vehicle.
2. Cut and strip the wires near the electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8267
3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of
each wire to the safety belt buckle pretensioner
wires.
4. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area
so that moveable parts do not contact the support
surface.
5. Remain at least 6.1 meters (20 feet) away from the safety belt buckle pretensioner assembly.
6. Deploy the safety belt buckle pretensioner by touching the other ends of the two wires to the
terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching
the deployed safety belt buckle pretensioner. 8. Dispose of the deployed safety belt buckle
pretensioner in the same manner as any other part to be scrapped.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8268
Seat Belt: Service and Repair Removal and Installation
Front Safety Belt
FRONT SAFETY BELT
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING:
- All safety belt assemblies including retractors, buckles, 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.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a pretensioner.
- The safety belt pretensioner is a pyrotechnic device. Never probe a pretensioner electrical
connector. Doing so could result in pretensioner or air bag deployment and could result in personal
injury.
- After deployment, the air bag surface could 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.
NOTE: Right side shown, left side similar.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8269
1. 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.
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 side impact sensors are located at or near the base of the B-pillars and C-pillars.
Disconnect the battery ground cable and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
When servicing the safety belt buckle pretensioner, deactivate the supplemental restraint system.
3. When servicing the safety belt buckle pretensioner, remove the affected seat from the vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8270
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8271
Part 2
4. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 2: Upper B-Pillar Trim Panel Removal Note
1. Remove the front and rear door opening weatherstrips along the entire length of the trim panel.
Item 5: Safety Belt Shoulder Height Adjuster Removal Note
1. Remove the safety belt shoulder height adjuster.
1 Rotate the safety belt shoulder height adjuster downward to release the lower tab.
2 Remove the safety belt shoulder height adjuster.
INSTALLATION
1. To install reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8272
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
When servicing the safety belt pretensioner, install the affected seat.
3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
When servicing the safety belt pretensioner, reactivate the supplemental restraint system (SRS).
4. 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.
When servicing the safety belt pretensioner, with all the restraint system diagnostic tools removed,
prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service
and Repair/Prove Out Procedure
5. Check the active restraint system for correct operation.
Item 2: Upper B-Pillar Trim Panel Installation Note
1. Raise the safety belt shoulder height adjuster and trim panel slider plate to the uppermost
position for correct installation.
Item 5: Safety Belt Shoulder Height Adjuster Installation Note
1. Rotate the safety belt shoulder height adjuster upward to engage the lower tab.
40/20/40
REAR SAFETY BELT - SECOND ROW,40/20/40
Safety Belt Bolt Bit
SPECIAL TOOL(S)
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.
NOTE: Second row outboard seats removed for clarity.
1. To access the second row outboard retractor or safety belt shoulder height adjuster remove the
quarter trim panel. 2. To access the second row center safety belt retractor, disassemble the rear
center seat backrest.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8273
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: LH Safety Belt Buckle Installation Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8274
1. The anti-rotation tab must be correctly aligned in the seat frame for correct installation.
Item 4: RH Dual Safety Belt Buckle Installation Note
1. The anti-rotation tab must be correctly aligned in the seat frame for correct installation.
60/40 Bench
REAR SAFETY BELT - SECOND ROW, 60/40 BENCH
Safety Belt Bolt Bit
SPECIAL TOOL(S)
REMOVAL
WARNING: All safety belt assemblies including retractors, buckles, 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. To access the second row 40 percent safety belt buckle, remove the seat from the vehicle. 2. To
access the second row outboard safety belt retractors, remove the rear quarter trim panels. 3. To
access the second row center safety belt retractor, remove and disassemble the 60 percent seat
backrest.
4. To remove the individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8275
Illustration 1 Of 2
5. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8276
Illustration 2 Of 2
6. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Third Row
REAR SAFETY BELT - THIRD ROW
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8277
Safety Belt Bolt Bit
SPECIAL TOOL(S)
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.
NOTE:
- RH side safety belt retractor shown, LH side similar.
- The third row seat has been removed for clarity.
1. Remove the rear quarter trim panel to access the third row retractor.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > General Procedures > Page 8278
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Page 8279
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Diagrams > Seat Belt Buckle Pretensioner, Driver
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Diagrams > Seat Belt Buckle Pretensioner, Driver > Page 8284
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Diagrams > Page 8285
Seat Belt Buckle: Description and Operation
SAFETY BELT BUCKLE AND PRETENSIONER
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from
the safety belt when deployed. The pretensioner works in conjunction with the front air bag system.
When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward,
removing excess webbing from the lap and shoulder safety belts.
If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt
pretensioners, a new driver and passenger seat belt system (including safety belt buckle and
pretensioners, safety belt retractors, and height adjusters), must be installed.
For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems.
For safety belt buckle pretensioner disposal information, refer to Air Bag Systems.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Driver
View 151-52
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Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Driver > Page 8290
View 151-60
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Driver
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Driver > Page 8293
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Page 8294
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the supplemental restraint system (SRS), the front safety belt buckles are equipped with
safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits
called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the
driver and passenger safety belt buckles. The safety belt buckle switches indicate to the restraints
control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this
information in determining the deployment rate of the dual-stage driver and passenger air bag
modules. The RCM also communicates the driver safety belt buckle switch status to the instrument
cluster module, which monitors the information to control the safety belt warning indicator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8299
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8300
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8301
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8302
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8303
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8304
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8305
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Description and Operation
Seat Belt Extension: Description and Operation
SAFETY BELT EXTENSION ASSEMBLY
In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in)
can be added to the belt length by using a safety belt extension. Safety belt extensions are
available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt
extensions are only available with black webbing.
Use only extensions manufactured by the same supplier as the safety belt. Manufacturer
identification is located at the end of the webbing on the label. Also, use the safety belt extension
only if the safety belt is too short for you when fully extended. Do not use an extension to change
the fit of the shoulder belt across the torso.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair
Seat Belt Height Adjuster: Service and Repair
SAFETY BELT SHOULDER HEIGHT ADJUSTER WITH STRIPPED WELD NUTS
D-Ring Installation Kit
SPECIAL TOOL(S)
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. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out
any chips before proceeding.
Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit
and tap new threads.
4. Use a threaded insert provided in the D-Ring Installation Kit and screw it into the retapped hole
until it is slightly below the surface.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Page 8312
5. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster.
Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times
to seat the insert keys.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Page 8313
D-Ring Installation Kit
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information
> Description and Operation
Seat Belt Reminder Buzzer: Description and Operation
Safety Belt Warning Indicator and Chime
The warning indicator and chime are reminders to fasten the safety belt. The system operates as
follows: If the driver safety belt is not buckled in the first six seconds after the ignition switch is turned to the
RUN or START position, the indicator will illuminate and the chime will toggle from on to off for six
seconds, for one minute.
- If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the
indicator and chime will turn off.
- If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides an additional reminder to the driver that the driver's safety belt is unbuckled by
intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument
cluster.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Description and Operation
Seat Belt Reminder Lamp: Description and Operation
Safety Belt Warning Indicator and Chime
The warning indicator and chime are reminders to fasten the safety belt. The system operates as
follows: If the driver safety belt is not buckled in the first six seconds after the ignition switch is turned to the
RUN or START position, the indicator will illuminate and the chime will toggle from on to off for six
seconds, for one minute.
- If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the
indicator and chime will turn off.
- If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides an additional reminder to the driver that the driver's safety belt is unbuckled by
intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument
cluster.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8328
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8334
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service Precautions > Customer Safety Information
Seat Belt Retractor: Customer Safety Information
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. Failure to replace the Belt and Retractor
assembly could increase the risk of injury in collisions.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service Precautions > Customer Safety Information > Page 8337
Seat Belt Retractor: Technician Safety Information
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. Failure to replace the belt and retractor
assembly could increase the risk of injury in collisions.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service Precautions > Page 8338
Seat Belt Retractor: Description and Operation
DUAL LOCKING MODE RETRACTORS
WARNING: After any vehicle collision, the safety belt system at all outboard seating positions
(except driver, which has no "automatic locking retractor" 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. Failure to replace the Belt and Retractor
assembly could increase the risk of injury in collisions.
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.
The automatic locking mode must be used when installing a child safety seat in the front or rear
passenger seating positions where dual locking mode retractors are provided.
Energy Management Retractor
This vehicle has a safety belt system with an energy management feature at the front seating
positions to help further reduce the risk of injury in the event of a head-on collision.
The energy management retractor feature is designed to pay out webbing in a controlled manner.
This feature is designed to help reduce the belt force acting on an occupant's chest.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service Precautions > Page 8339
Seat Belt Retractor: Service and Repair
AUTOMATIC LOCKING RETRACTOR - EVALUATION OF LOCKABILITY AND RELEASE
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. 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 correct 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 correctly, 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Tensioner: > 03-11-3 > Jun > 03 > Restraint System - Air Bag
Lamp ON/DTC B2292 Set
Seat Belt Tensioner: Customer Interest Restraint System - Air Bag Lamp ON/DTC B2292 Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Tensioner: > 03-11-3 > Jun > 03 > Restraint System - Air Bag
Lamp ON/DTC B2292 Set > Page 8348
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Tensioner: > 03-11-3 > Jun > 03 > Restraint
System - Air Bag Lamp ON/DTC B2292 Set
Seat Belt Tensioner: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC
B2292 Set
Article No. 03-11-3
06/09/03
ELECTRICAL - AIRBAG WARNING LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE
(DTC) B2292
FORD: 2002-2003 EXPLORER
MERCURY: 2002-2003 MOUNTAINEER
ISSUE Some 2002-2003 4Dr Explorer/Mountaineer vehicles may exhibit an air bag warning lamp
illuminated with Diagnostic Trouble Code (DTC) B2292 and Light Flashing Code (LFC) 33 (Driver
seat pretensioner fault) OR LFC 34 (Passenger seat pretensioner fault). This may be caused by
intermittent pretensioner connection at either seat belt buckle.
ACTION Install pretensioner kit for affected side(s) by build date/color. Refer to the following
Service Information for details.
SERVICE INFORMATION
Obtain correct Service Kit and refer to instruction sheet included with kit for installation instructions.
2002 Model Year Through 3/3/02 Build Dates
^ Medium Dark Parchment 1L2Z-78610E22-AAA
^ Midnight Black 1L2Z-78610E22-AAB
^ Dark Graphite 1L2Z-78610E22-AAC
2002/2003 Model Years 3/4/02 Through 1/17/03
^ Medium Dark Parchment 1L2Z-78610E22-BAA
^ Midnight Black 1L2Z-78610E22-BAB
^ Dark Graphite 1L2Z-78610E22-BAC
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
031103A Install Pretensioner Wiring 1.3 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
031103B Install Pretensioner Wiring 1.6 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform
Deactivation/Reactivation)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Tensioner: > 03-11-3 > Jun > 03 > Restraint
System - Air Bag Lamp ON/DTC B2292 Set > Page 8354
031103C Install Pretensioner Wiring 1.5 Hrs.
Kit One Front Seat (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
031103D Install Pretensioner Wiring 1.8 Hrs.
Kit Both Front Seats (Includes Time To Remove And Install Seat And To Perform Deactivation And
Reactivation - With Canopy Air Bag)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7861202 X2
OASIS CODES: 104000, 203200, 206000
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Seat Belt Buckle Pretensioner, Driver
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Seat Belt Buckle Pretensioner, Driver > Page 8357
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 8358
Seat Belt Tensioner: Service Precautions
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet)
away to ensure personal safety. Due to the loud report which occurs when the safety belt
pretensioner is deployed, hearing protection is required.
- Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that
moveable parts contact the support surface, as the forces of the deploying pretensioner can cause
it to ricochet and cause personal injury.
- Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep
fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an
accidental deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Safety Belt Buckle and Pretensioner
Seat Belt Tensioner: Description and Operation Safety Belt Buckle and Pretensioner
SAFETY BELT BUCKLE AND PRETENSIONER
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from
the safety belt when deployed. The pretensioner works in conjunction with the front air bag system.
When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward,
removing excess webbing from the lap and shoulder safety belts.
If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt
pretensioners, a new driver and passenger seat belt system (including safety belt buckle and
pretensioners, safety belt retractors, and height adjusters), must be installed.
For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems.
For safety belt buckle pretensioner disposal information, refer to Air Bag Systems.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Safety Belt Buckle and Pretensioner > Page 8361
Seat Belt Tensioner: Description and Operation Air Bag and Safety Belt Pretensioner SRS
SAFETY BELT PRETENSIONERS
As part of the SRS the safety belt buckles ate equipped with pretensioners. The safety belt buckle
pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated
by the restraints control module (RCM) when the module detects a crash event force exceeding a
programmed limit.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Deployed
Seat Belt Tensioner: Service and Repair Deployed
SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED
1. WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses
when repairing an air bag equipped vehicle
and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never
probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag
deployment and could result in personal injury.
Dispose of the deployed safety belt pretensioner in the same manner as any other part to be
scrapped.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Deployed > Page 8364
Seat Belt Tensioner: Service and Repair Undeployed
Inoperative
SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, INOPERATIVE
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep
fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an
accidental deployment.
NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have
been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and
safety belt retractor pretensioners must be treated the same as any inoperative live safety belt
buckle pretensioner or safety belt retractor pretensioner being returned.
1. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from
the vehicle. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt
retractor pretensioner to Ford Motor Company.
Scrapped Vehicle
SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, SCRAPPED VEHICLE
REMOTE DEPLOYMENT
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet)
away to ensure personal safety. Due to the loud report which occurs when the safety belt
pretensioner is deployed, hearing protection is required.
- Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that
moveable parts contact the support surface, as the forces of the deploying pretensioner can cause
it to ricochet and cause personal injury.
1. Remove the safety belt buckle pretensioner assembly from the vehicle.
2. Cut and strip the wires near the electrical connector.
3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of
each wire to the safety belt buckle pretensioner
wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Service and Repair > Deployed > Page 8365
4. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area
so that moveable parts do not contact the support
surface.
5. Remain at least 6.1 meters (20 feet) away from the safety belt buckle pretensioner assembly.
6. Deploy the safety belt buckle pretensioner by touching the other ends of the two wires to the
terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching
the deployed safety belt buckle pretensioner. 8. Dispose of the deployed safety belt buckle
pretensioner in the same manner as any other part to be scrapped.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams > Page 8369
Seat Sensor/Switch: Service Precautions
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
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams > Page 8370
Seat Sensor/Switch: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a hall-effect sensor located on the driver seat track. The seat track
position sensor informs the restraints control module (RCM) of the driver seat position. Based on
programmed limits, the seat track position sensor will inform the RCM of the driver seat position.
The RCM uses this information in determining the deployment rate of the dual-stage driver air bag
module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams > Page 8371
Seat Sensor/Switch: Service and Repair
SEAT POSITION SENSOR
Special Tool(s)
SPECIAL 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.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. NOTE: The seat position sensor is mounted at the LH rear of the seat track.
Position the driver seat forward enough so that upon removal the sensor can clear the magnetic
bar and bracket.
2. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams > Page 8372
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable and wait at least one minute.
3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplement restraint system (SRS).
4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Remove the driver seat.
5. Remove the components in the order indicated in the illustration and table.
Item 5: Seat Position Sensor Removal Note
1. NOTE: Make note of the wire harness routing for installation purposes.
Disconnect the seat position sensor electrical connector.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams > Page 8373
To install, reverse the removal procedure
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Install the driver seat. After installation, position the driver seat from its forward most position to its rearmost position and
then back again. While positioning the seat, make sure that the seat position sensor, the magnet
and bracket and the wire harness do not come in contact with any other part of the seat that may
cause damage.
3. Connect the battery ground cable.
4. 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.
With the restraint system diagnostic tools installed at all deployable devices, prove out the
supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and
Repair/Prove Out Procedure
5. Disconnect the battery ground cable and wait at least one minute.
6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
7. Connect the battery ground cable.
8. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
Item 5: Seat Position Sensor Installation Note
1. NOTE: Route the wire harness as noted during removal.
Connect the seat position sensor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Diagrams > Page 8374
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Front Impact Severity Sensor
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Front Impact Severity Sensor > Page 8380
View 151-60
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Front Impact Severity Sensor > Page 8381
View 151-52
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Front Impact Severity Sensor > Page 8382
View 151-40
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Front Impact Severity Sensor > Page 8383
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Front Impact Severity Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Front Impact Severity Sensor > Page 8386
Impact Sensor: Diagrams Side Impact Sensor
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Front Impact Severity Sensor > Page 8387
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Front Impact Severity Sensor > Page 8388
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Front Impact Severity Sensor > Page 8389
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Customer Safety Information
Impact Sensor: Customer Safety Information
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Customer Safety Information > Page 8392
Impact Sensor: Technician Safety Information
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 reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- The tightening torque of the air bag front impact severity sensor retaining bolts is critical for
correct system operation.
- 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.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Customer Safety Information > Page 8393
Impact Sensor: Vehicle Damage Warnings
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service Precautions > Page 8394
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
For these vehicles, the SRS uses up to five satellite sensors in addition to the RCM. The RCM is
mounted to the center tunnel beneath the console. All vehicles will have a front impact severity
sensor and it is located in the front-center of the vehicle, mounted under the lower radiator support.
If the vehicle is equipped with safety canopies, there are four additional side impact sensors. The
four additional sensors are located at the base of each B-pillar and C-pillar. The LH and RH C-pillar
mounted side impact sensors are not interchangeable. Mounting orientation is critical for correct
operation of all impact and rollover sensors.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation
Impact Sensor: Service and Repair Removal and Installation
Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
Special Tool(s)
SPECIAL TOOL(S)
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.
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. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8397
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolts is
critical for correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation
portion of this procedure.
- Make sure the lower radiator support and front impact severity sensor bracket mating surfaces
are clean and debris free.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8398
With all the restraint system diagnostic tools removed prove out the supplemental restraint system
(SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out
Procedure
Item 3: Front Impact Severity Sensor Installation Note
1. Align the locator tab of the front impact severity sensor mounting bracket to the opening in the
lower radiator support sheet metal.
First Row, B-Pillar
SIDE IMPACT SENSOR - FIRST ROW, B-PILLAR
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped
with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or
any other damaged supplemental restraint system (SRS) components whether or not the air bag is
deployed.
NOTE:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8399
- 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.
- The driver side is shown, the passenger side is similar.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. Remove the B-pillar trim panel.
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. WARNING: The tightening torque of the air bag side impact sensor retaining bolt is critical for
correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8400
To install, reverse the removal procedure
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out
Procedure
8. Check the active restraint system for correct operation.
Item 3: Side Impact Sensor Installation Note
1. Make sure the bolt, washer and clip are in place on the side impact sensor before installing it to
the vehicle.
2. Align the locator pegs to the openings in the B-pillar sheet metal.
Second Row, C-Pillar
SIDE IMPACT SENSOR
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8401
Special Tool(s)
SPECIAL TOOL(S)
REMOVAL
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped
with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or
any other damaged supplemental restraint system (SRS) components whether or not the air bag is
deployed.
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.
- The RH side is shown, the LH side is similar.
- The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8402
Part 1
Part 2
3. Remove the components in the order indicated in the illustration and table.
Item 4: Quarter Trim Panel Removal Note
1. Pull out on the rear quarter trim panel at the C-pillar to release the retaining clips and access the
C-pillar side impact sensor.
INSTALLATION
1. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for
correct system operation.
NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
To install, reverse the removal procedure.
2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all
deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure
4. Disconnect the battery ground cable and wait at least one minute.
5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8403
Reactivate the supplemental restraint system (SRS).
6. Connect the battery ground cable.
7. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out
Procedure
8. Check the active restraint system for correct operation.
Item 7: Side Impact Sensor Installation Note
1 Align the locator tab of the second row side impact sensor mounting bracket to the opening in the
C-pillar sheet metal.
Item 3: Safety Belt Anchor Installation Note
1. NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Position the safety belt anchor and install the bolt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8404
Impact Sensor: Service and Repair General Procedures
Missing Weld Nut
WELD NUT REPAIR - MISSING WELD NUT
CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair.
NOTE: C-pillar repair shown, others similar.
1. Remove the component from where the weld nut is to be repaired.
2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face
will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32
in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding
screw (self-tapping).
5. Set up for the positioning of the weld nut.
1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent
access hole.
2 Position a weld nut, shoulder end up, onto the wire.
3 Position a flat washer onto the wire and secure it so it cannot be pulled off.
6. Plug weld the weld nut into position.
1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the welding wire through and stop against the sheet metal.
2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal.
3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled
previously.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Removal and Installation > Page 8405
7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the
previously obtained screw.
10. Tighten the attaching screws to specification.
Stripped Weld Nut
WELD NUT REPAIR - STRIPPED WELD NUT
1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and
surrounding area for repair.
- If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn,
then a threaded insert will have to be installed. Follow the instructions with the thread insert repair
kit.
3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit.
Then tap, using an 8 mm by 1.25 bit.
- Do not oversize a 6 mm weld nut by more than 8 mm.
4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit.
Then tap, using a 10 mm by 1.50 bit.
- Do not oversize an 8 mm weld nut by more than 10 mm.
5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7.
Tighten the attaching screws to specification.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Page 8406
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Driver
View 151-52
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Driver > Page 8411
View 151-60
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Driver > Page 8414
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Page 8415
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the supplemental restraint system (SRS), the front safety belt buckles are equipped with
safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits
called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the
driver and passenger safety belt buckles. The safety belt buckle switches indicate to the restraints
control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this
information in determining the deployment rate of the dual-stage driver and passenger air bag
modules. The RCM also communicates the driver safety belt buckle switch status to the instrument
cluster module, which monitors the information to control the safety belt warning indicator.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 8419
Seat Sensor/Switch: Service Precautions
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
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 8420
Seat Sensor/Switch: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a hall-effect sensor located on the driver seat track. The seat track
position sensor informs the restraints control module (RCM) of the driver seat position. Based on
programmed limits, the seat track position sensor will inform the RCM of the driver seat position.
The RCM uses this information in determining the deployment rate of the dual-stage driver air bag
module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 8421
Seat Sensor/Switch: Service and Repair
SEAT POSITION SENSOR
Special Tool(s)
SPECIAL 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.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE:
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. NOTE: The seat position sensor is mounted at the LH rear of the seat track.
Position the driver seat forward enough so that upon removal the sensor can clear the magnetic
bar and bracket.
2. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 8422
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable and wait at least one minute.
3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplement restraint system (SRS).
4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Remove the driver seat.
5. Remove the components in the order indicated in the illustration and table.
Item 5: Seat Position Sensor Removal Note
1. NOTE: Make note of the wire harness routing for installation purposes.
Disconnect the seat position sensor electrical connector.
INSTALLATION
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
installation portion of this procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 8423
To install, reverse the removal procedure
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Install the driver seat. After installation, position the driver seat from its forward most position to its rearmost position and
then back again. While positioning the seat, make sure that the seat position sensor, the magnet
and bracket and the wire harness do not come in contact with any other part of the seat that may
cause damage.
3. Connect the battery ground cable.
4. 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.
With the restraint system diagnostic tools installed at all deployable devices, prove out the
supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and
Disarming/Service and Repair/Prove Out Procedure
5. Disconnect the battery ground cable and wait at least one minute.
6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
7. Connect the battery ground cable.
8. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out
Procedure
Item 5: Seat Position Sensor Installation Note
1. NOTE: Route the wire harness as noted during removal.
Connect the seat position sensor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Diagrams > Page 8424
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8430
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8431
Accessory Delay Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8432
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information >
Service and Repair
Antenna, Radio: Service and Repair
ANTENNA
REMOVAL
1. Remove the antenna mast. 2. Remove the RH front fender splash shield.
View 1 Of 2
3. View 1 of 2. Disconnect the components in the order indicated in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information >
Service and Repair > Page 8437
View 2 Of 2
4. View 2 of 2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Application and ID
Alarm Module: Application and ID
For further information regarding the Central Security Module, please refer to Body Control Module
/ Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 8445
Alarm System Transponder: Service and Repair
PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER
REMOVAL
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams > Page 8446
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Antitheft Mode Switch >
Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Antitheft Mode Switch >
Component Information > Locations > Page 8450
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Antitheft Mode Switch >
Component Information > Locations > Page 8451
Antitheft Mode Switch: Service and Repair
ANTI-THEFT ALARM INHIBIT SWITCH
REMOVAL
1. Remove the driver door trim panel. 2. Position the watershield aside.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Anti-Theft Alarm Inhibit Switch Installation Note
1. The anti-theft alarm inhibit switch mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For
Alarm) > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For
Alarm) > Component Information > Locations > Page 8455
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8461
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8462
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A626 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8463
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8464
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8465
Keyless Entry Key-Pad: Service and Repair
KEYLESS ENTRY KEYPAD
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Door Glass Top Run Removal Note
1. Position the door glass top run aside to access the door pillar trim panel screws.
INSTALLATION
1. To Install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Application and ID
Keyless Entry Module: Application and ID
For further information regarding the Remote Keyless Entry Module, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair
Keyless Entry Transmitter: Service and Repair
REMOTE TRANSMITTER PROGRAMMING
NOTE: All remote transmitters are programmable and must be set at the same time.
1. Make sure that the anti-theft system is not armed or triggered and key code programming is not
active. 2. Press the driver door lock control switch UNLOCK button. 3. Turn the key from OFF to
ON 8 times within 10 seconds, ending in ON. if the program mode is successfully entered the doors
will lock and
unlock to confirm.
4. Press any button on a remote transmitter, and the doors will lock and then unlock all doors to
confirm that the remote transmitter is programmed.
All remote transmitters must be programmed within 20 seconds. Up to four remote transmitters can
be programmed to the vehicle security module each time programming mode is entered.
5. If the door locks do not respond for any remote transmitter, wait several seconds and press the
button again. If the door locks still fail to respond,
refer to Power Locks.
6. NOTE: Exiting is acknowledged by locking and unlocking the doors if at least one remote
transmitter has been programmed.
Exiting the programming mode is accomplished if one of the following occurring: The key transitions to OFF.
20 seconds have passed since entering programming mode or since the last remote transmitter
was programmed.
- Four remote transmitters have been programmed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations
View 151-9
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 8476
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 8477
Parking Assist Control Module: Service and Repair
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8486
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8487
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8488
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8489
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8495
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8496
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8497
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8498
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 8501
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 8502
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 8503
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Page 8504
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
REMOVAL
1. Remove the rear bumper.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Parking Aid Sensor Removal Note
1. Press the retaining tabs to remove the parking aid sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Switch > Component Information > Locations
View 151-27
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Switch > Component Information > Locations > Page 8508
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Switch > Component Information > Locations > Page 8509
Parking Assist Switch: Service and Repair
PARKING AID SWITCH
REMOVAL
1. Remove the instrument cluster finish panel.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Parking Aid Switch Removal Note
1 Press the retaining tabs to remove the parking aid switch.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 8516
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > Information and Message Center
Driver/Vehicle Information Display: Description and Operation Information and Message Center
INFORMATION AND MESSAGE CENTER
The message center is a green vacuum fluorescent, fixed format display, integrated into the lower
RH corner of the instrument cluster. The message center functions are controlled by the message
center switches. The message center displays important vehicle information by constantly
monitoring different vehicle systems. The message center will notify the driver of a potential vehicle
problem by displaying a warning message pertaining to the system in which a fault has been
detected.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > Information and Message Center > Page 8519
Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It
Work?)
PRINCIPLES OF OPERATION
The message center electronic functions use both hardwired, standard corporate protocol (SCP),
and UART based protocol (UBP) communication networks to transmit and receive information. It is
very important to understand:
- where the input (command) originates from.
- all the information (messages) necessary in order for a feature to operate.
- which module(s) receive(s) the input or command message.
- does the module which received the input (message) control the output of the feature, or does it
output a message over the SCP or UBP communication network to another module?
- which module controls the output of the feature.
The message center provides the following features:
- information displays
- setup displays
- warning messages
- system check messages
The message center information can be selected through a set of three switches:
- INFO
- SETUP
- RESET
Tire Pressure Monitoring System
The following messages may appear if the vehicle is equipped with a tire pressure monitoring
system: CHECK TIRE PRESSURE
- CHECK SPARE TIRE PRESSURE
- WARNING TIRE VERY LOW
- TIRE PRESSURE SYSTEM OFF
- TIRE PRESSURE SYSTEM FAULT
- TIRE PRESSURE SENSOR FAULT
General information on these messages may also be found in the owner literature.
Information Displays
The information displays are non-timed modes. The selected mode remains on until the driver
presses a message center switch to change the mode or it is overridden by another mode. The
information display modes are: odometer
- trip odometer
- compass
- distance to empty
- average fuel economy
Setup Displays
The setup displays are timed modes and terminate after a finite interval. The setup display modes
are: language
- English/metric units
- system check
- oil life status
- oil life in xx%
- charge system status
- oil pressure status
- engine temp status
- washer fluid level
- brake fluid level
- fuel level status
- distance to empty
- tire warning
Every 180 days or 8,000 km (5,000 miles) the oil life display in the message center SYSTEM
CHECK will decrease gradually from 100% to 0%. At 5% oil life, the CHANGE OIL SOON warning
indicator will illuminate. At 0% oil life, the OIL CHANGE REQUIRED warning indicator will
illuminate. Oil life status is continually displayed in the SYSTEM CHECK portion of the message
center and oil life warnings appear if oil life is low.
Warning Messages
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > Information and Message Center > Page 8520
The warning messages are single cycle, non-resettable and repetitive warning messages. The
single cycle warning messages are: CHANGE OIL SOON
- OIL CHANGE REQUIRED
- LOW WASHER FLUID LEVEL
- LOW BRAKE FLUID LEVEL
The single cycle warning messages will display once whenever the key is turned to ON or a fault
occurs in a system and can be cleared by pressing the RESET button.
The repetitive warning messages are: CHECK CHARGING SYSTEM
- TRANSMISSION OVERHEATED
- CHECK TRANSMISSION
- LOW FUEL LEVEL
- LOW OIL PRESSURE
- CHECK ENGINE TEMPERATURE
- CHECK TIRE PRESSURE
- CHECK FUEL CAP
The repetitive warning messages are displayed at a fixed interval whenever the key is turned ON or
is in the ACC position. To remove a repetitive warning message, press the RESET button. The
message will only reoccur after 10 minutes or until the warning condition is corrected.
The tire pressure warning is displayed whenever the tire pressure module receives a signal from a
tire pressure sensor, indicating that the tire pressure is out of range.
The non-resettable warning messages will display whenever the key is turned to ON and a fault
occurs in a system. The fault must be corrected to clear the non-resettable warning messages.
The non-resettable warning messages are: DOOR AJAR
- BACKUP AID
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
NOTE:
- A new instrument cluster must be reconfigured.
- When installing a new instrument cluster, it is necessary to contact the Instrument Cluster
Program.
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link
connector and select the vehicle to be tested from the diagnostic tool
menu. If the diagnostic 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 position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
- SCP+ or SCP- circuit fault; all electronic control units no response/not equipped, refer to Module
Communications Network (Information Bus).
- No response/not equipped for the instrument cluster, GO to Pinpoint Test G. See: Instrument
Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint
Tests/Test G
- System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the
continuous DTCs and carry out self-test diagnostics for the instrument cluster.
7. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic
Trouble Code (DTC) Index to continue diagnostics.
See: Diagnostic Trouble Code Descriptions
8. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
See: Symptom Related Diagnostic Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8523
DTC Index B1205 - U2013
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8524
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8525
Symptom Chart, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8526
Driver/Vehicle Information Display: Pinpoint Tests
Compass Sensor Module C909
Instrument Cluster C220a
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8527
Instrument Cluster C220b
Message Center Switch C253
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8528
Washer Fluid Level Switch C138
Tests AJ
PINPOINT TEST AJ: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY
Test AJ1
Normal Conditions
The message center display is located in the instrument cluster The instrument cluster odometer
display and message center display are contained in the same window.
Possible Causes
- instrument cluster
- message center switch
Tests AK
PINPOINT TEST AK: THE COMPASS IS INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8529
Test AK1-AK2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8530
Test AK3
Normal Conditions
The compass sensor module receives power from circuit 1003 (GY/YE) and is grounded through
circuit 1203 (BK/LB). The compass sensor module communicates vehicle direction to the
instrument cluster to be displayed in the message center. The compass sensor module utilizes
circuit 702 (WH/BK) and circuit 703 (WH/OG) to communicate to the instrument cluster.
Possible Causes
- circuit 1003 (GY/YE) open
- circuit 1203 (BK/LB) open
- circuit 702 (WH/BK) open or short
- circuit 703 (WH/OG) open or short
- compass sensor module
Tests AL
PINPOINT TEST AL: THE COMPASS IS INACCURATE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8531
Test AL1-AL3
Normal Operation
The compass sensor module communicates vehicle direction to the instrument cluster to be
displayed in the message center.
Possible Causes
- compass sensor module
- vehicle is magnetized
Tests AM
PINPOINT TEST AM: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
Test AM1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8532
Test AM2-AM4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8533
Test AM5
Normal Operation
The message center switch assembly uses circuits 231 (BK/YE) and 1411 (GY/OG) to
communicate the requested switch function to the message center.
Possible Causes
- circuit 231 (BK/YE) open or shorted to ground
- circuit 1411 (GY/OG) open or shorted to ground
- instrument cluster
- message center switch
Tests AN
PINPOINT TEST AN: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW WASHER
FLUID LEVEL DISPLAY
Test AN1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8534
Test AN2-AN4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8535
Test AN5
Normal Conditions
The washer fluid level switch circuit 81 (RD/LG) is open when the washer fluid level is high. When
the washer fluid level is low, the switch will close circuit 81 (RD/LG) with the ground circuit 1203
(BK/LB) to signal the message center to indicate the washer fluid level is low.
Possible Causes
- circuit 1203 (BK/LB) open
- circuit 81 (RD/LG) open or short
- instrument cluster
- washer fluid level switch
Tests AO
PINPOINT TEST AO: THE INDICATOR DOES NOT OPERATE CORRECTLY - DOOR AJAR
DISPLAY
Test AO1-AO3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8536
Test AO4-AO5
Normal Conditions
The vehicle security module communicates the door ajar status to the message center over the
UART based protocol (UBP) communication network, circuit 693 (OG).
Possible Causes
- door ajar switch
- instrument cluster
- vehicle security module
Tests AP
PINPOINT TEST AP: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW FUEL LEVEL
DISPLAY
Test AP1-AP2
Normal Conditions
The instrument cluster communicates the fuel level status to the message center.
Possible Causes
- fuel pump module
- instrument cluster
Tests AQ
PINPOINT TEST AQ: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW BRAKE
FLUID LEVEL DISPLAY
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8537
Test AQ1-AQ2
Normal Conditions
The instrument cluster communicates the brake fluid level status to the message center.
Possible Causes
- brake fluid level switch
- instrument cluster
Tests AR
PINPOINT TEST AR: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW OIL
PRESSURE DISPLAY
Test AR1-AR2
Normal Conditions
The instrument cluster communicates the oil pressure status to the message center.
Possible Causes
- engine oil pressure switch
- instrument cluster
Tests AS
PINPOINT TEST AS: THE INDICATOR DOES NOT OPERATE CORRECTLY - CHECK ENGINE
TEMPERATURE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8538
Test AS1-AS2
Normal Conditions
The instrument cluster communicates the engine temperature status to the message center.
Possible Causes
- engine oil pressure switch
- instrument cluster
Tests AT
PINPOINT TEST AT: THE INDICATOR DOES NOT OPERATE CORRECTLY - BACK-UP AID
Test AT1-AT3
Normal Conditions
The parking aid module communicates the backup aid status to the message center using
hardwired circuit 1435 (VT/OG) and ISO communication circuit 70 (LB/WH).
Possible Causes
- parking aid module
- instrument cluster
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Page 8539
Driver/Vehicle Information Display: Service and Repair
MESSAGE CENTER
REMOVAL
1. Remove the instrument cluster center finish panel.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Message Center Switch Removal Note
1. Press the retaining tabs to remove the message center switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Page 8540
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-24-1 > Dec > 04 > Entertainment System - Rear Seat
DVD Player Rattling
DVD Player: Customer Interest Entertainment System - Rear Seat DVD Player Rattling
TSB 04-24-1
12/13/04
RATTLE OR VIBRATION FROM REAR SEAT ENTERTAINMENT SYSTEM DVD PLAYER DEALER INSTALLED UNIT
FORD: 2003-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2003-2005 Mountaineer
ISSUE Some 2003-2005 Explorer 4dr/Mountaineer and Aviator vehicles equipped with a moon roof
and dealer installed DVD entertainment system, may exhibit a rattle/vibration from the rear seat
entertainment system DVD player while driving over rough surfaces.
ACTION Install a reinforcement bracket kit. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
EYE AND HAND PROTECTION IS RECOMMENDED WHEN PERFORMING THIS PROCEDURE.
NOTE
BE SURE TO PROTECT THE INTERIOR OF THE VEHICLE DURING THIS PROCEDURE.
NOTE
THE RIVETS PROVIDED IN THE REINFORCEMENT KIT MUST BE USED. DO NOT
SUBSTITUTE WITH DIFFERENT SIZES OR STYLES AS THIS WILL RESULT IN
INTERFERENCE WHEN OPERATING THE MOON ROOF SUNSHADE.
NOTE
KEEP THE SUNSHADE IN THE FULL FORWARD POSITION THROUGHOUT THE ENTIRE
PROCEDURE TO AVOID DAMAGE.
1. Close the moon roof slide sunshade (full forward position).
2. Remove DVD unit from headliner by removing the four (4) center screws (flip DVD screen down
for access), one (1) screw front center of DVD player, and unplug the electrical connectors.
3. Remove headliner per Workshop Manual Section 501-01.
4. Remove DVD mounting bracket from moon roof assembly by disengaging the DVD wire
anchors. Remove two (2) screws at rear and then slide the bracket rearward to disengage the three
(3) tabs at the front.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-24-1 > Dec > 04 > Entertainment System - Rear Seat
DVD Player Rattling > Page 8550
5. Place the moon roof cross member reinforcement bracket from the kit onto the moon roof cross
member, center and retain with clamps (Figures 1 and 2).
NOTE
DO NOT CLAMP ON THE MOON ROOF PANEL OR SUNSHADE PANEL ALUMINUM TRACKS
AS THIS CAN CAUSE DEFORMATION AND/OR DAMAGE.
NOTE
FOR THE REMAINDER OF THIS PROCEDURE WHEN DRILLING IS REQUIRED, USE A DRILL
STOP. BEGIN BY SETTING THE DRILL STOP AT 1/2" (13 MM). THE DRILL STOP CAN BE
ADJUSTED TO DRILL SLIGHTLY DEEPER IF NEEDED. DAMAGE TO THE ROOF COULD
OCCUR IF DRILLED TOO DEEP.
6. Using a 1/8" drill bit with stop, drill through the moon roof cross member using the rivet holes in
the reinforcement bracket as a guide (Figure 2).
7. Prepare the TA-1 Motorcraft Metal Bonding Adhesive. Insert adhesive cartridge into the
dispensing gun. Squeeze a small amount of adhesive out until each side is flowing from cartridge.
This will level the plungers. Attach the mixing tip and dispense a small amount of adhesive to verify
it is evenly mixed and that color is consistent.
NOTE
PERFORM STEPS 8 AND 9 ON ONE SIDE AT A TIME.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-24-1 > Dec > 04 > Entertainment System - Rear Seat
DVD Player Rattling > Page 8551
8. Remove the three (3) screws that secure the side bracket to the body side roof rail and moon
roof track (Figure 3). Retrieve the corresponding side bracket from the kit. Apply 0.2" (5 mm) beads
of TA-1 adhesive to the kit bracket (Figure 4) and place against the existing side bracket. Secure
by reinstalling the three (3) screws (Figure 5).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-24-1 > Dec > 04 > Entertainment System - Rear Seat
DVD Player Rattling > Page 8552
9. Using a 1/8" drill bit with stop, drill through all rivet holes in side reinforcement into the body side
rail (Figure 6). Install rivets from kit (Figure 7). Repeat on opposite side.
10. Un-clamp and remove reinforcement bracket and remove metal chips. Apply 0.2" (5 mm) beads
of TA-i adhesive to the moon roof cross member. Do not apply adhesive over the slots in the cross
member (Figure 8).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-24-1 > Dec > 04 > Entertainment System - Rear Seat
DVD Player Rattling > Page 8553
11. Place the reinforcement bracket back onto the cross member. Align pre-drilled holes and clamp
in place. Secure the reinforcement bracket with rivets from kit (apply on the tangents of the
reinforcement bracket so the glue will contact the moonroof bracket). (Figures 9 and 10).
12. Check to ensure that none of the rivets are protruding up into the path of the sunshade travel. If
necessary flatten rivets on the sunshade side.
13. Reinstall DVD mounting bracket being sure to locate the stops of the three (3) tabs against the
edge of the cross member slots, it may be necessary to slightly pry the center front edge. Secure
with all screws.
14. Carefully check operation of moon roof sunshade and moon roof.
15. Re-anchor DVD wire and check that all fasteners and screws are secure.
16. Reinstall headliner per Workshop Manual Section 501-01.
17. Reinstall DVD.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042401A Install The Reinforcement 2.5 Hrs.
Bracket Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-24-1 > Dec > 04 > Entertainment System - Rear Seat
DVD Player Rattling > Page 8554
7850244 33
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles
DVD Player: Customer Interest Entertainment System - Rear Seat DVD Player Rattles
TSB 04-17-3
09/06/04
RATTLE FROM REAR SEAT ENTERTAINMENT SYSTEM (RES) DVD PLAYER
FORD: 2003-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2003-2005 Mountaineer
ISSUE
Some 2003-2005 Explorer 4dr/Mountaineer and Aviator vehicles equipped with a moon roof and
DVD entertainment system, may exhibit a rattle noise from the rear seat entertainment system
(RES) DVD player while driving over rough surfaces.
ACTION
To service, install a Reinforcement Bracket Kit. Refer to the following Service Procedure.
PARTS BLOCK
SERVICE PROCEDURE
NOTE
EYE AND HAND PROTECTION IS SUGGESTED WHEN PERFORMING THIS PROCEDURE.
NOTE
BE SURE TO PROTECT THE INTERIOR OF THE VEHICLE DURING THIS PROCEDURE.
NOTE
THE RIVETS PROVIDED IN THE REINFORCEMENT KIT MUST BE USED. DO NOT
SUBSTITUTE WITH DIFFERENT SIZES OR STYLES AS THIS WILL RESULT IN
INTERFERENCE WHEN OPERATING THE MOON ROOF SUNSHADE.
NOTE
KEEP THE SUNSHADE IN THE FULL FORWARD POSITION THROUGHOUT THE ENTIRE
PROCEDURE TO AVOID DAMAGE.
1. Close the moon roof slide sunshade (full forward position).
2. Remove DVD unit from headliner by removing two (2) center screws (flip DVD screen down for
access), one (1) screw LH side (open storage door to access), and detaching three (3) clips (1-LH,
2-RH side). Unplug electrical connector. Refer to Workshop Manual Section 415-00.
3. Remove headliner per Workshop Manual Section 501-01.
4. Remove DVD mounting bracket from moon roof assembly by disengaging the DVD wire
anchors. Remove the two (2) screws on each side, two (2) screws at rear and then slide the
bracket rearward to disengage the three (3) tabs at the front.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles > Page 8559
5. Place the moon roof cross member reinforcement bracket from the Kit onto the moon roof cross
member, center and retain with clamps (Figures 1 and 2).
NOTE
DO NOT CLAMP ON THE MOON ROOF PANEL OR SUNSHADE PANEL ALUMINUM TRACKS
AS THIS CAN CAUSE DEFORMATION AND/OR DAMAGED.
NOTE
FOR THE REMAINDER OF THIS PROCEDURE WHEN DRILLING IS REQUIRED, BEGIN BY
SETTING THE DRILL STOP AT 13 MM (1/2"). THE DRILL STOP CAN BE ADJUSTED TO DRILL
SLIGHTLY DEEPER IF NEEDED. DAMAGE TO THE ROOF COULD OCCUR IF DRILLED TOO
DEEP.
6. Using a 1/8" drill bit with stop, drill through the moon roof cross member using the rivet holes in
the reinforcement bracket as a guide (Figure 2).
7. Preparation of TA-1 Motorcraft Metal Bonding Adhesive.
a. Insert adhesive cartridge into the dispensing gun.
b. Squeeze a small amount of adhesive out until each side is flowing from cartridge. This will level
the plungers.
c. Attach the mixing tip and dispense a small amount of adhesive to verify it is evenly mixed and
that color is consistent.
NOTE
PERFORM STEP 8 AND 9 ON ONE SIDE AT A TIME.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles > Page 8560
8. Remove the three (3) screws that secure the side bracket to the body side roof rail and moon
roof track (Figure 3). Retrieve the corresponding side bracket from the Kit. Apply 5 mm beads of
TA-1 adhesive to the Kit bracket (Figure 4) and place against the existing side bracket. Secure by
reinstalling the three (3) screws (Figure 5).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles > Page 8561
9. Using a 1/8" drill bit with stop, drill through all rivet holes in side reinforcement into the body side
rail (Figure 6). Install rivets from Kit (Figure 7). Repeat on opposite side.
10. Un-clamp and remove reinforcement bracket and remove metal chips. Apply 5 mm beads of
TA-1 adhesive to the moon roof cross member. Do not apply adhesive over the slots in the cross
member (Figure 8).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles > Page 8562
11. Place the reinforcement bracket back onto the cross member. Align pre-drilled holes and clamp
in place. Secure the reinforcement bracket with rivets from Kit (Figures 9 and 10).
12. Check to ensure that none of the rivets are protruding up into the path of the sunshade travel. If
necessary flatten rivets on the sunshade side.
13. Take the DVD mounting bracket and place on a work bench. Using the measurements provided
in (Figure 11), accurately lay out the rivet holes to be drilled. Drill holes using a 1/8" drill bit.
14. Reinstall DVD mounting bracket being sure to locate the stops of the three (3) tabs against the
edge of the cross member slots, it may be necessary to slightly pry the center front edge. Secure
with all screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles > Page 8563
15. Using the rivet holes drilled into the DVD mounting bracket as a guide, drill through both the
reinforcement bracket and cross member (Figure 12). Clean out chips and secure with rivets from
Kit (Figure 13).
16. Check again that none of the rivets are protruding into the path of the sunshade travel. If
necessary, flatten rivets on sunshade side.
17. Carefully check operation of moon roof sunshade and moon roof.
18. Re-anchor DVD wire and check that all fasteners and screws are secure.
19. Reinstall headliner per Workshop Manual Section 501-01.
20. Reinstall DVD.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041703A Install The 2.5 Hr.
Reinforcement Bracket Kit: 2003-2005 Explorer/ Mountaineer/ Aviator
DEALER CODING
CONDITION
BASIC PART NO. CODE
7850244 33
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-17-3 > Sep > 04 > Entertainment System - Rear Seat
DVD Player Rattles > Page 8564
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-14-6 > Jul > 04 > Entertainment Systems - DVD Player
Screen Latch Rattle
DVD Player: Customer Interest Entertainment Systems - DVD Player Screen Latch Rattle
TSB 04-14-6
07/26/04
RATTLE FROM DVD SCREEN LATCH ASSEMBLY
FORD: 2003-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2003-2005 Mountaineer
ISSUE
Some 2003-2005 Explorer 4drlMountaineerlAviator vehicles equipped with a factory installed DVD
player may exhibit a rattling noise coming from the flip down screen latch assembly.
ACTION
To repair, replace the DVD screen latch assembly.
Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
IT IS NOT NECESSARY TO REMOVE THE DVD ASSEMBLY FROM THE VEHICLE DURING
THIS REPAIR.
NOTE
NO TOOLS ARE REQUIRED FOR THIS REPAIR.
1. Position the DVD screen in the down position.
2. Gently pull the latch out from the bottom of the DVD screen.
3. Install the new latch, making sure that the latch is lined up with the grooves in the body of the
screen and gently sliding the latch into place.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041406A Replace The DVD Screen 0.2 Hr.
Latch Assembly
DEALER CODING
CONDITION
BASIC PART NO. CODE
10E956 33
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Customer Interest: > 04-14-6 > Jul > 04 > Entertainment Systems - DVD Player
Screen Latch Rattle > Page 8569
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-24-1 > Dec > 04 > Entertainment System Rear Seat DVD Player Rattling
DVD Player: All Technical Service Bulletins Entertainment System - Rear Seat DVD Player Rattling
TSB 04-24-1
12/13/04
RATTLE OR VIBRATION FROM REAR SEAT ENTERTAINMENT SYSTEM DVD PLAYER DEALER INSTALLED UNIT
FORD: 2003-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2003-2005 Mountaineer
ISSUE Some 2003-2005 Explorer 4dr/Mountaineer and Aviator vehicles equipped with a moon roof
and dealer installed DVD entertainment system, may exhibit a rattle/vibration from the rear seat
entertainment system DVD player while driving over rough surfaces.
ACTION Install a reinforcement bracket kit. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
EYE AND HAND PROTECTION IS RECOMMENDED WHEN PERFORMING THIS PROCEDURE.
NOTE
BE SURE TO PROTECT THE INTERIOR OF THE VEHICLE DURING THIS PROCEDURE.
NOTE
THE RIVETS PROVIDED IN THE REINFORCEMENT KIT MUST BE USED. DO NOT
SUBSTITUTE WITH DIFFERENT SIZES OR STYLES AS THIS WILL RESULT IN
INTERFERENCE WHEN OPERATING THE MOON ROOF SUNSHADE.
NOTE
KEEP THE SUNSHADE IN THE FULL FORWARD POSITION THROUGHOUT THE ENTIRE
PROCEDURE TO AVOID DAMAGE.
1. Close the moon roof slide sunshade (full forward position).
2. Remove DVD unit from headliner by removing the four (4) center screws (flip DVD screen down
for access), one (1) screw front center of DVD player, and unplug the electrical connectors.
3. Remove headliner per Workshop Manual Section 501-01.
4. Remove DVD mounting bracket from moon roof assembly by disengaging the DVD wire
anchors. Remove two (2) screws at rear and then slide the bracket rearward to disengage the three
(3) tabs at the front.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-24-1 > Dec > 04 > Entertainment System Rear Seat DVD Player Rattling > Page 8575
5. Place the moon roof cross member reinforcement bracket from the kit onto the moon roof cross
member, center and retain with clamps (Figures 1 and 2).
NOTE
DO NOT CLAMP ON THE MOON ROOF PANEL OR SUNSHADE PANEL ALUMINUM TRACKS
AS THIS CAN CAUSE DEFORMATION AND/OR DAMAGE.
NOTE
FOR THE REMAINDER OF THIS PROCEDURE WHEN DRILLING IS REQUIRED, USE A DRILL
STOP. BEGIN BY SETTING THE DRILL STOP AT 1/2" (13 MM). THE DRILL STOP CAN BE
ADJUSTED TO DRILL SLIGHTLY DEEPER IF NEEDED. DAMAGE TO THE ROOF COULD
OCCUR IF DRILLED TOO DEEP.
6. Using a 1/8" drill bit with stop, drill through the moon roof cross member using the rivet holes in
the reinforcement bracket as a guide (Figure 2).
7. Prepare the TA-1 Motorcraft Metal Bonding Adhesive. Insert adhesive cartridge into the
dispensing gun. Squeeze a small amount of adhesive out until each side is flowing from cartridge.
This will level the plungers. Attach the mixing tip and dispense a small amount of adhesive to verify
it is evenly mixed and that color is consistent.
NOTE
PERFORM STEPS 8 AND 9 ON ONE SIDE AT A TIME.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-24-1 > Dec > 04 > Entertainment System Rear Seat DVD Player Rattling > Page 8576
8. Remove the three (3) screws that secure the side bracket to the body side roof rail and moon
roof track (Figure 3). Retrieve the corresponding side bracket from the kit. Apply 0.2" (5 mm) beads
of TA-1 adhesive to the kit bracket (Figure 4) and place against the existing side bracket. Secure
by reinstalling the three (3) screws (Figure 5).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-24-1 > Dec > 04 > Entertainment System Rear Seat DVD Player Rattling > Page 8577
9. Using a 1/8" drill bit with stop, drill through all rivet holes in side reinforcement into the body side
rail (Figure 6). Install rivets from kit (Figure 7). Repeat on opposite side.
10. Un-clamp and remove reinforcement bracket and remove metal chips. Apply 0.2" (5 mm) beads
of TA-i adhesive to the moon roof cross member. Do not apply adhesive over the slots in the cross
member (Figure 8).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-24-1 > Dec > 04 > Entertainment System Rear Seat DVD Player Rattling > Page 8578
11. Place the reinforcement bracket back onto the cross member. Align pre-drilled holes and clamp
in place. Secure the reinforcement bracket with rivets from kit (apply on the tangents of the
reinforcement bracket so the glue will contact the moonroof bracket). (Figures 9 and 10).
12. Check to ensure that none of the rivets are protruding up into the path of the sunshade travel. If
necessary flatten rivets on the sunshade side.
13. Reinstall DVD mounting bracket being sure to locate the stops of the three (3) tabs against the
edge of the cross member slots, it may be necessary to slightly pry the center front edge. Secure
with all screws.
14. Carefully check operation of moon roof sunshade and moon roof.
15. Re-anchor DVD wire and check that all fasteners and screws are secure.
16. Reinstall headliner per Workshop Manual Section 501-01.
17. Reinstall DVD.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042401A Install The Reinforcement 2.5 Hrs.
Bracket Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-24-1 > Dec > 04 > Entertainment System Rear Seat DVD Player Rattling > Page 8579
7850244 33
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles
DVD Player: All Technical Service Bulletins Entertainment System - Rear Seat DVD Player Rattles
TSB 04-17-3
09/06/04
RATTLE FROM REAR SEAT ENTERTAINMENT SYSTEM (RES) DVD PLAYER
FORD: 2003-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2003-2005 Mountaineer
ISSUE
Some 2003-2005 Explorer 4dr/Mountaineer and Aviator vehicles equipped with a moon roof and
DVD entertainment system, may exhibit a rattle noise from the rear seat entertainment system
(RES) DVD player while driving over rough surfaces.
ACTION
To service, install a Reinforcement Bracket Kit. Refer to the following Service Procedure.
PARTS BLOCK
SERVICE PROCEDURE
NOTE
EYE AND HAND PROTECTION IS SUGGESTED WHEN PERFORMING THIS PROCEDURE.
NOTE
BE SURE TO PROTECT THE INTERIOR OF THE VEHICLE DURING THIS PROCEDURE.
NOTE
THE RIVETS PROVIDED IN THE REINFORCEMENT KIT MUST BE USED. DO NOT
SUBSTITUTE WITH DIFFERENT SIZES OR STYLES AS THIS WILL RESULT IN
INTERFERENCE WHEN OPERATING THE MOON ROOF SUNSHADE.
NOTE
KEEP THE SUNSHADE IN THE FULL FORWARD POSITION THROUGHOUT THE ENTIRE
PROCEDURE TO AVOID DAMAGE.
1. Close the moon roof slide sunshade (full forward position).
2. Remove DVD unit from headliner by removing two (2) center screws (flip DVD screen down for
access), one (1) screw LH side (open storage door to access), and detaching three (3) clips (1-LH,
2-RH side). Unplug electrical connector. Refer to Workshop Manual Section 415-00.
3. Remove headliner per Workshop Manual Section 501-01.
4. Remove DVD mounting bracket from moon roof assembly by disengaging the DVD wire
anchors. Remove the two (2) screws on each side, two (2) screws at rear and then slide the
bracket rearward to disengage the three (3) tabs at the front.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles > Page 8584
5. Place the moon roof cross member reinforcement bracket from the Kit onto the moon roof cross
member, center and retain with clamps (Figures 1 and 2).
NOTE
DO NOT CLAMP ON THE MOON ROOF PANEL OR SUNSHADE PANEL ALUMINUM TRACKS
AS THIS CAN CAUSE DEFORMATION AND/OR DAMAGED.
NOTE
FOR THE REMAINDER OF THIS PROCEDURE WHEN DRILLING IS REQUIRED, BEGIN BY
SETTING THE DRILL STOP AT 13 MM (1/2"). THE DRILL STOP CAN BE ADJUSTED TO DRILL
SLIGHTLY DEEPER IF NEEDED. DAMAGE TO THE ROOF COULD OCCUR IF DRILLED TOO
DEEP.
6. Using a 1/8" drill bit with stop, drill through the moon roof cross member using the rivet holes in
the reinforcement bracket as a guide (Figure 2).
7. Preparation of TA-1 Motorcraft Metal Bonding Adhesive.
a. Insert adhesive cartridge into the dispensing gun.
b. Squeeze a small amount of adhesive out until each side is flowing from cartridge. This will level
the plungers.
c. Attach the mixing tip and dispense a small amount of adhesive to verify it is evenly mixed and
that color is consistent.
NOTE
PERFORM STEP 8 AND 9 ON ONE SIDE AT A TIME.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles > Page 8585
8. Remove the three (3) screws that secure the side bracket to the body side roof rail and moon
roof track (Figure 3). Retrieve the corresponding side bracket from the Kit. Apply 5 mm beads of
TA-1 adhesive to the Kit bracket (Figure 4) and place against the existing side bracket. Secure by
reinstalling the three (3) screws (Figure 5).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles > Page 8586
9. Using a 1/8" drill bit with stop, drill through all rivet holes in side reinforcement into the body side
rail (Figure 6). Install rivets from Kit (Figure 7). Repeat on opposite side.
10. Un-clamp and remove reinforcement bracket and remove metal chips. Apply 5 mm beads of
TA-1 adhesive to the moon roof cross member. Do not apply adhesive over the slots in the cross
member (Figure 8).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles > Page 8587
11. Place the reinforcement bracket back onto the cross member. Align pre-drilled holes and clamp
in place. Secure the reinforcement bracket with rivets from Kit (Figures 9 and 10).
12. Check to ensure that none of the rivets are protruding up into the path of the sunshade travel. If
necessary flatten rivets on the sunshade side.
13. Take the DVD mounting bracket and place on a work bench. Using the measurements provided
in (Figure 11), accurately lay out the rivet holes to be drilled. Drill holes using a 1/8" drill bit.
14. Reinstall DVD mounting bracket being sure to locate the stops of the three (3) tabs against the
edge of the cross member slots, it may be necessary to slightly pry the center front edge. Secure
with all screws.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles > Page 8588
15. Using the rivet holes drilled into the DVD mounting bracket as a guide, drill through both the
reinforcement bracket and cross member (Figure 12). Clean out chips and secure with rivets from
Kit (Figure 13).
16. Check again that none of the rivets are protruding into the path of the sunshade travel. If
necessary, flatten rivets on sunshade side.
17. Carefully check operation of moon roof sunshade and moon roof.
18. Re-anchor DVD wire and check that all fasteners and screws are secure.
19. Reinstall headliner per Workshop Manual Section 501-01.
20. Reinstall DVD.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041703A Install The 2.5 Hr.
Reinforcement Bracket Kit: 2003-2005 Explorer/ Mountaineer/ Aviator
DEALER CODING
CONDITION
BASIC PART NO. CODE
7850244 33
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-17-3 > Sep > 04 > Entertainment System Rear Seat DVD Player Rattles > Page 8589
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-14-6 > Jul > 04 > Entertainment Systems DVD Player Screen Latch Rattle
DVD Player: All Technical Service Bulletins Entertainment Systems - DVD Player Screen Latch
Rattle
TSB 04-14-6
07/26/04
RATTLE FROM DVD SCREEN LATCH ASSEMBLY
FORD: 2003-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2003-2005 Mountaineer
ISSUE
Some 2003-2005 Explorer 4drlMountaineerlAviator vehicles equipped with a factory installed DVD
player may exhibit a rattling noise coming from the flip down screen latch assembly.
ACTION
To repair, replace the DVD screen latch assembly.
Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
IT IS NOT NECESSARY TO REMOVE THE DVD ASSEMBLY FROM THE VEHICLE DURING
THIS REPAIR.
NOTE
NO TOOLS ARE REQUIRED FOR THIS REPAIR.
1. Position the DVD screen in the down position.
2. Gently pull the latch out from the bottom of the DVD screen.
3. Install the new latch, making sure that the latch is lined up with the grooves in the body of the
screen and gently sliding the latch into place.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041406A Replace The DVD Screen 0.2 Hr.
Latch Assembly
DEALER CODING
CONDITION
BASIC PART NO. CODE
10E956 33
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-14-6 > Jul > 04 > Entertainment Systems DVD Player Screen Latch Rattle > Page 8594
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Other Service Bulletins for DVD Player: > 05-3-4 > Feb > 05 > Body Moonroof Squeak or Rattle Noise
Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Moonroof Squeak or Rattle Noise
TSB 05-3-4
02/21/05
MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer
4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise
coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail
assembly. A new corner insert is now available to correct the condition (Figure 2).
ACTION The corner inserts are located in both front corners of the moonroof track and can be
accessed by cycling the moonroof glass to the full open position. The original corner insert design
had snap tabs that may break off during installation, creating a rattle condition. Replace both of the
original inserts and remove any broken tabs left in the track. Refer to the following Service
Procedure.
SERVICE PROCEDURE
1. Open the moonroof to the full open position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Other Service Bulletins for DVD Player: > 05-3-4 > Feb > 05 > Body Moonroof Squeak or Rattle Noise > Page 8600
2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver
and inspect the snap tabs (Figures 1 and 2).
3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose
debris (Figure 3).
4. Install a new corner insert on both sides (Figure 4).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Other Service Bulletins for DVD Player: > 05-3-4 > Feb > 05 > Body Moonroof Squeak or Rattle Noise > Page 8601
OPERATION DESCRIPTION TIME
050304A 2001-2003 Explorer Sport, 0.3Hr.
2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator:
Replace Both Of The Moonroof Corner Inserts
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502B36 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Other Service Bulletins for DVD Player: > 05-3-4 > Feb > 05 > Body Moonroof Squeak or Rattle Noise > Page 8607
2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver
and inspect the snap tabs (Figures 1 and 2).
3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose
debris (Figure 3).
4. Install a new corner insert on both sides (Figure 4).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > All Other Service Bulletins for DVD Player: > 05-3-4 > Feb > 05 > Body Moonroof Squeak or Rattle Noise > Page 8608
OPERATION DESCRIPTION TIME
050304A 2001-2003 Explorer Sport, 0.3Hr.
2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator:
Replace Both Of The Moonroof Corner Inserts
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502B36 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Page 8609
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Technical Service Bulletins > Page 8610
DVD Player: Service and Repair
DIGITAL VERSATILE DISC (DVD) PLAYER
REMOVAL
1. Disconnect the battery.
2. Remove the components in the order indicated in the illustration and table.
Item 1: DVD Screws Removal Note
1. Open the DVD display and the storage compartment.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations
Electronic Features Component Location Index
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 8614
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) universal transmitter with a door opening system that
lacks stop and reverse features as required by federal standards. This includes any garage door
opening system manufactured before April 1, 1982.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 8615
Garage Door Opener Transmitter: Description and Operation
UNIVERSAL TRANSMITTER
The HomeLink (R) universal transmitter, located on the overhead console, provides a convenient
way to substitute up to three hand-held transmitters with a single built-in device. The transmitter will
learn the radio frequency codes of most current transmitters to operate garage doors, entry gates,
security systems, and home or office lighting.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of 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 cause is not visually evident, verify the symptom and
GO to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8618
Symptom Chart
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8619
Garage Door Opener Transmitter: Pinpoint Tests
Universal Transmitter C928
Test A
PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE
Test A1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8620
Test A2-A4
Normal Operation
Under normal operation the HomeLink (R) universal transmitter can be programmed to operate up
to three garage doors, entry gates, security systems, and home or office lighting. Voltage is
supplied to the module via circuit 705 (LG/OG). Circuit 205 (BK) provides the module ground.
Possible Causes
- circuit 705 (LG/OG) open or short to ground
- circuit 1205 (BK) open
- HomeLink(R) universal transmitter
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 8621
Garage Door Opener Transmitter: Service and Repair
UNIVERSAL TRANSMITTER PROGRAMMING
WARNING: A garage door opening system that cannot stop or reverse itself after detecting an
object in its path does not meet current federal safety standards. To decrease the risk of serious
injury or death, do not use this HomeLink (R) universal transmitter with a door opening system that
lacks stop and reverse features as required by federal standards. This includes any garage door
opening system manufactured before April 1, 1982.
1. 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.
Verify the hand-held transmitter is operative.
2. Prepare for programming the universal transmitter by erasing all three channels (hold down the
two outside buttons until the red light begins to
flash). 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. NOTE: For Canadian vehicles only: 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.
Use both hands to press the hand-held transmitter button and the desired button on the universal
transmitter. Do not release either button.
6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and
then rapidly. Release both buttons when the rapid
flashing begins. The universal transmitter has successfully learned the new frequency signal and
can be used in place of the hand-held transmitter(s).
7. 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.
To operate, simply press the appropriate button on the universal transmitter. The red light is on
while the signal is being transmitted.
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 owner literature.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 8622
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. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures
for programming.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 8623
73III Automotive Meter
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Application and ID
Memory Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations > Page 8631
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations > Page 8632
Seat Memory Switch: Testing and Inspection
MEMORY SET SWITCH
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, install a new switch; otherwise, return to
the calling Pinpoint Test.
NOTE: Refer to Multimeter User's Manual for testing diodes.
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, install a new switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Module >
Component Information > Application and ID
Pedal Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Specifications
Pedal Positioning Motor: Specifications
Adjustable pedal motor cable ..............................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Page 8644
Amplifier: Service and Repair
SUBWOOFER AMPLIFIER
REMOVAL
1. Disconnect the battery. 2. Remove the LH rear quarter trim panel.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear > Page 8649
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear > Page 8650
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear > Page 8651
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Speaker
Speaker: Service and Repair Door Speaker
DOOR SPEAKER
NOTE: The removal and installation procedures apply to all original equipment door-mounted
speakers.
REMOVAL
1. Remove the door trim panel.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Speaker > Page 8654
Speaker: Service and Repair Speaker Enclosure - Subwoofer
SPEAKER ENCLOSURE - SUBWOOFER
REMOVAL
1. Disconnect the battery. 2. Remove the LH rear quarter trim panel.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8660
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8661
Accessory Delay Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8662
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Application and ID
Alarm Module: Application and ID
For further information regarding the Central Security Module, please refer to Body Control Module
/ Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Application and ID
Keyless Entry Module: Application and ID
For further information regarding the Remote Keyless Entry Module, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations
View 151-9
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8672
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8673
Parking Assist Control Module: Service and Repair
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Pedal Positioning Module > Component Information > Application and ID
Pedal Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Antitheft Mode Switch > Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Antitheft Mode Switch > Component Information > Locations > Page 8681
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Antitheft Mode Switch > Component Information > Locations > Page 8682
Antitheft Mode Switch: Service and Repair
ANTI-THEFT ALARM INHIBIT SWITCH
REMOVAL
1. Remove the driver door trim panel. 2. Position the watershield aside.
3. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Anti-Theft Alarm Inhibit Switch Installation Note
1. The anti-theft alarm inhibit switch mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8686
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8695
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8696
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8697
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings > Page 8698
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid
Warnings
TSB 05-6-4
04/04/05
FALSE PARKING AID WARNINGS
FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition,
Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar
LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 05-4-19 to update the description for labor operation F.
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 PROCEDURE
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:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8704
BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE:
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 to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS
observe the following four 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).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8705
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.
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, SELECT:
^ Tool box Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
NOTE
FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A
PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE
COLOR.
REFER TO PAINTING INSTRUCTIONS BELOW.
PAINTING INSTRUCTIONS
^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle
^ Surface can be cleaned with Isopropyl alcohol
^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour
^ Maximum coating thickness 125 micro meters (including the primer)
^ Paint or veil of paint must not get into connector
^ Immersion processes ARE NOT permitted
^ Paint must be applied evenly to the surface
^ Functional test must be done after painting
^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec.
to 1500 micro sec.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050604A 2004-2005 F150, 0.7 Hr.
2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003
Blackwood, 2005 Freestyle: Replace
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8706
One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not
Use With 12651D, 12651D8, P101)
050604B 2003-2005 Aviator, 0.9 Hr.
2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES
Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2004-2005 Monterey, 0.8 Hr.
2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S)
INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604B 2003-2005 Expedition: 1.3 Hrs.
Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal
(Do Not Use With 12651D, 12651D8, P101)
050604C 2004-2005 Monterey, 1.2 Hrs.
2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT
Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D,
12651D8, P101)
050604D 2003-2005 Escape, 2005 0.5 Hr.
Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For
Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101)
050604E 2003-2005 Escape, 2005 0.9 Hr.
Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover
Removal (Do Not Use With 12651D, 12651D8, P101)
050604F Additional Time To Paint 1.0 Hr.
Sensors To Match Bumper Cover On The Following Vehicles: Aviator,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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: > 05-6-4 > Apr > 05 > Instruments - False Parking Aid Warnings >
Page 8707
Monterey, Five Hundred, Freestyle, Montego
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 8710
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 8711
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Outer Left > Page 8712
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8713
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
REMOVAL
1. Remove the rear bumper.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Parking Aid Sensor Removal Note
1. Press the retaining tabs to remove the parking aid sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Switch > Component Information > Locations
View 151-27
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Switch > Component Information > Locations > Page 8717
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Switch > Component Information > Locations > Page 8718
Parking Assist Switch: Service and Repair
PARKING AID SWITCH
REMOVAL
1. Remove the instrument cluster finish panel.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Parking Aid Switch Removal Note
1 Press the retaining tabs to remove the parking aid switch.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8724
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8725
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8726
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8727
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8728
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8729
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8730
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8731
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8732
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8733
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8734
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8735
Trailer Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8736
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8737
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8738
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8739
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8740
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8741
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8742
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8743
Trailer Connector: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8744
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8745
Trailer Connector: Electrical Diagrams
Trailer/Camper Adapter
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1, System Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8746
95-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8747
95-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8748
95-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions
Trailer Lamps: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8753
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8754
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8755
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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Information > Diagrams > Diagram Information and Instructions > Page 8758
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Symbols Part 2
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Symbols Part 3
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Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Symbols Part 5
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8763
Systems Overview
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8764
Trailer Lamps: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8770
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8771
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8772
Trailer Lamps: Electrical Diagrams
Trailer/Camper Adapter
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1, System Overview
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95-2
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95-3
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95-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
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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
Trailer Lamps: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating
correctly. If not, refer to the appropriate pinpoint test. See: Pinpoint Tests 3. Visually inspect for
obvious signs of mechanical or electrical damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuse(s): 13 (40A)
- 20 (30A)
- 27 (20A)
- Central junction box (CJB) fuse 25 (5A)
- Circuitry
- Relay(s)
- Bulb(s)
NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are
all functioning correctly with the trailer disconnected.
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 5. If the concern is not visually evident, verify the symptom and
GO to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8778
Symptom Chart
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8779
Trailer Lamps: Pinpoint Tests
Trailer Tow Battery Charge Relay C4021, C4022
TRAILER TOW BATTERY CHARGE RELAY C4021, TRAILER TOW PARKING LAMP RELAY
C4022
Trailer Tow Battery Charge Relay C4021, Trailer Tow Parking Lamp Relay C4022
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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 8780
Trailer Tow C439 (4-pin Connector)
Trailer Tow C473 (7-pin Connector), Part 1
Trailer Tow C473 (7-pin Connector), Part 2
Trailer Tow C1187, C1188, C4023
TRAILER TOW RH TURN RELAY C1187, TRAILER LOW LH TURN RELAY C1188, TRAILER
TOW REVERSING LAMP RELAY C4023
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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 8781
Trailer Tow RH Turn Relay C1187, Trailer Tow LH Turn Relay C1188, Trailer Tow Reversing Lamp
Relay C4023, Part 1
Trailer Tow RH Turn Relay C1187, Trailer Tow LH Turn Relay C1188, Trailer Tow Reversing Lamp
Relay C4023, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8782
Trailer Tow Electronic Brake Control Module C239
Test Y
PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE
Test Y1
Normal Operation
Circuit 14 (BN) supplies power to the exterior lamps and the coil side of the trailer tow parking lamp
relay. When the trailer tow parking lamp relay is energized, voltage received from circuit 1043
(DG/YE) is switched to the trailer tow connector through circuit 962 (BN/WH). Ground is supplied to
the trailer tow parking lamp relay through circuit 1205 (BK).
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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 8783
Possible Causes
- trailer
Test Z
PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - RH TRAILER TURN
SIGNALS/STOPLAMPS/HAZARD LAMPS
Test Z1-Z3
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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 8784
Test Z4-Z5
Normal Operation
When the RH trailer tow turn relay is energized, power is routed from circuit 175 (BK/YE) to the
trailer tow connector through circuit 64 (DG). When circuit 378 (BN/YE) is supplied power from the
multifunction switch (such as when the brakes are applied or the RH turn signal is engaged), the
RH turn relay is energized. Ground is supplied to the trailer tow turn lamp relays through circuit
1205 (BK).
Possible Causes
- circuit 64 (DG) open
- circuit 175 (BK/YE) open
- circuit 378 (BN/YE) open
- circuit 1205 (BK) open
- trailer tow turn lamp relay
- trailer
Tests AA
PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - LH TRAILER TURN
SIGNAL/STOPLAMP/HAZARD LAMPS
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AA1-AA3
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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 8786
Test AA4-AA5
Normal Operation
When the LH trailer tow turn relay is energized, power is routed from circuit 175 (BK/YE) to the
trailer tow connector through circuit 52 (YE). When circuit 374 (DB/WH) is supplied power from the
multifunction switch (such as when the brakes are applied or the LH turn signal is engaged), the LR
turn relay is energized.
Possible Causes
- circuit 52 (YE) open
- circuit 175 (BK/YE) open
- circuit 374 (DB/WH) open
- circuit 1205 (BK) open
- trailer tow turn lamp relay
- trailer
Tests AB
PINPOINT TEST AB: THE TRAILER LAMPS ON INOPERATIVE - PARKING LAMPS
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8787
Test AB1-AB3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8788
Test AB4-AB5
Normal Operation
Circuit 14 (BN), under normal operation, supplies power to the exterior lamps and the coil side of
the trailer tow parking lamp relay. When the trailer tow parking lamp relay is energized, voltage
received from circuit 1043 (DG/YE) is switched to the trailer tow connector through circuit 962
(BN/WH). Ground is supplied to the trailer tow parking lamp relay through circuit 1205 (BK).
Possible Causes
- circuit 14 (BN) open
- circuit 962 (BN/WH) open
- circuit 1043 (DG/YE) open
- circuit 1205 (BK) open
- trailer tow parking lamp relay
- trailer
Tests AC
PINPOINT TEST AC: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS
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Test AC1-AC3
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AC4-AC5
Normal Operation
Circuit 140 (BK/PK) supplies power to the reversing lamps and the coil side of the trailer tow
reversing lamp relay. When the trailer tow reversing lamp relay is energized, voltage received from
circuit 1043 (DG/YE) is switched to the trailer tow connector through circuit 963 (BK/LG). Ground is
supplied to the trailer tow reversing lamp relay through circuit 1205 (BK).
Possible Causes
- circuit 140 (BK/PK) open
- circuit 963 (BK/LG) open
- circuit 1043 (DG/YE) open
- circuit 1205 (BK) open
- trailer tow reversing lamp relay
- trailer
Tests AD
PINPOINT TEST AD: THE TRAILER LAMPS ARE ON CONTINUOUSLY
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Test AD1-AD4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Test AD5-AD7
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AD7 Continued
Normal Operation
Circuit 14 (BN) supplies power to the exterior lamps and the coil side of the trailer tow parking lamp
relay. When the trailer tow parking lamp relay is energized, voltage received from circuit 1043
(DG/YE) is switched to the trailer tow connector through circuit 962 (BN/WH). Circuit 140 (BK/PK)
supplies power to the reversing lamps and the coil side of the trailer tow reversing lamp relay.
When the trailer tow reversing lamp relay is energized, voltage received from circuit 1043 (DG/YE)
is switched to the trailer tow connector through circuit 963 (BK/LG).
Possible Causes
- circuit 52 (YE) short to power
- circuit 64 (DG) short to power
- circuit 962 (BN/WH) short to power
- circuit 963 (BK/LG) short to power
- trailer tow reversing lamp relay
- trailer tow parking lamp relay
- trailer tow RH turn or LH turn relay
- trailer
Tests AE
PINPOINT TEST AE: THE TRAILER BATTERY CHARGING IS INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8794
Test AE1-AE3
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AE4-AE5
Normal Operation
The trailer battery charging is accomplished through the use of the trailer tow battery charge relay.
Power is supplied to the trailer tow battery charge relay by circuit 175 (BK/YE) and when
energized, provides power to the trailer tow connector through circuit 49 (OG). The control circuit
for the trailer tow battery charge relay is provided by circuit 1003 (GY/YE) Ground is provided to the
trailer tow battery charge relay through circuit 1205 (BK).
Possible Causes
- circuit 49 (OG) open
- circuit 175 (BK/YE) open
- circuit 1003 (GY/YE) open
- circuit 1205 (BK) open
- trailer tow battery charge relay
- trailer
Tests AF
PINPOINT TEST AF: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AF1-AF2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AF3-AF4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Test AF5
Normal Operation
The trailer tow electronic brake control module receives power through circuit 1051 (PK/WH) and
provides output power to the trailer tow connector through circuit 43 (DB). The trailer tow electronic
brake control module is grounded through circuit 1205 (BK). The trailer tow electronic brake control
module also receives input when the parking lamps are illuminated through circuit 14 (BN) and the
BPP switch through circuit 511 (LG) when the brake pedal is applied.
Possible Causes
- circuit 14 (BN) open
- circuit 43 (DB) open, shorted to power or shorted to ground
- circuit 511 (LG) open
- circuit 1051 (PK/WH) open
- circuit 1205 (BK) open
- trailer tow electronic brake control module
- trailer
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73III Automotive Meter
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 8804
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 8805
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 8808
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 8809
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 8810
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 8811
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8814
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8815
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8816
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8817
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8818
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8819
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8820
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8821
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 8822
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8827
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8828
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8829
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8830
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8831
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8832
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8833
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8834
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8835
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8836
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8837
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8838
Trailer Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8839
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8840
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8841
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8842
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8843
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8844
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8845
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8846
Trailer Connector: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8847
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8848
Trailer Connector: Electrical Diagrams
Trailer/Camper Adapter
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1, System Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8849
95-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8850
95-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8851
95-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations > Central Security Module
View 151-44
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations > Central Security Module > Page 8858
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8861
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8862
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8863
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8864
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8865
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8866
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8867
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8868
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8869
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8870
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8871
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8872
Body Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8873
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8874
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8875
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8876
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8877
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8878
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8879
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8880
Body Control Module: Connector Views
Central Security Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8881
Driver Seat Module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8882
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8883
Body Control Module: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
59-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 8884
59-2
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service
Bulletins > Recalls for Auxiliary Step / Running Board: > NHTSA03V094000 > Mar > 03 > Recall 03V094000: Running
Board Wiring Defect
Auxiliary Step / Running Board: Recalls Recall 03V094000: Running Board Wiring Defect
DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running
boards manufactured by Southern Comfort, which include courtesy lights manufactured by
American Technology Components, Inc., might overheat when the wire harness is exposed to
excessive moisture and road salt. This overheating condition can cause the running board to melt
or cause a fire.
REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has
reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service
Bulletins > By Symptom for Auxiliary Step / Running Board: > NHTSA03V094000 > Mar > 03 > Recall 03V094000: Running
Board Wiring Defect
Auxiliary Step / Running Board: By Symptom Recall 03V094000: Running Board Wiring Defect
DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running
boards manufactured by Southern Comfort, which include courtesy lights manufactured by
American Technology Components, Inc., might overheat when the wire harness is exposed to
excessive moisture and road salt. This overheating condition can cause the running board to melt
or cause a fire.
REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has
reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service
Bulletins > All Technical Service Bulletins for Auxiliary Step / Running Board: > NHTSA03V094000 > Mar > 03 > Recall
03V094000: Running Board Wiring Defect
Auxiliary Step / Running Board: All Technical Service Bulletins Recall 03V094000: Running Board
Wiring Defect
DEFECT: Some sport utility vehicle, pickup truck, and minivan conversions equipped with running
boards manufactured by Southern Comfort, which include courtesy lights manufactured by
American Technology Components, Inc., might overheat when the wire harness is exposed to
excessive moisture and road salt. This overheating condition can cause the running board to melt
or cause a fire.
REMEDY: Dealers will replace the wiring harness on these running boards. The manufacturer has
reported that owner notification began March 7, 2003. Owners may contact Southern Comfort at 1800-745-6096.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service
Bulletins > Page 8903
Auxiliary Step / Running Board: Service and Repair
RUNNING BOARD
NOTE: Explorer is shown, Mountaineer is similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
2. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
FRONT DOOR HANDLE
NOTE: LH side shown, RH side similar.
REMOVAL
1. Remove the front door trim panel. 2. Position the watershield aside.
3. NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which will fit only one lock. If a new key is
used, the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 8914
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair > Page 8915
Part 2
4. Remove the components in the order indicated in the illustration and table.
Item 2: Electrical Connectors Removal Note
1. Disconnect the door latch jumper harness electrical connectors.
1 If removing the door latch, disconnect the door harness electrical connector.
2 If equipped, disconnect the key cylinder switch electrical connector and separate the locator from
the door frame.
Item 4: Door Lock Cylinder Removal Note
1. Release the lock cylinder actuating rod.
- If a new lock cylinder is being installed, remove the retaining clip, the lock cylinder lever and the
lock cylinder switch.
Item 12: Interior Door Handle Cable Locators Removal Note
1. Release the cable locators from the door frame.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service Precautions
Front Door Panel: Service Precautions
CAUTION: To avoid damaging the trim panel, do not pull directly outward to carry out this step.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service Precautions > Page 8919
Front Door Panel: Service and Repair
FRONT DOOR TRIM PANEL
NOTE: RH side is shown. LH side is similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 5: Front Door Trim Panel Removal Note
CAUTION: To avoid damaging the trim panel, do not pull directly outward to carry out this step.
1. Lift the door trim panel by pulling directly upward on the armrest to disengage the panel clips.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System
Information > Adjustments
Front Door Striker: Adjustments
STRIKER ADJUSTMENT
1. Loosen the door latch striker bolts.
2. Adjust the door latch striker plate from side to side or up and down as necessary.
3. Tighten the door latch striker plate bolts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
DOOR WINDOW GLASS - FRONT
REMOVAL
1. Remove the front door speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair > Page 8926
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair > Page 8927
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Front Door Window Glass-to-Regulator Bolts Removal Note
NOTE: Some vehicles may use rivets to attach the window.
1. Lower the front door window glass as necessary to access bolts.
2. If removing the front door regulator assembly and motor, secure the front door glass in the full up
position with tape.
Item 4: Front Door Window Glass Removal Note
1. Pull glass out through the top inboard side of the door.
Item 12: Glass Top Run Channel Assembly Removal Note
1. Remove the top glass run channel thorough the top opening of the front door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Left Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Diagrams > Left Front > Page 8932
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
WINDOW GLASS - FRONT DOOR
REMOVAL
1. Remove the front door speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8936
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8937
2. Remove the components in the order indicated in the illustration and table.
To remove individual components, only carry out the listed steps.
3. To install, reverse the removal procedure.
Item 2: Front Door Weatherstrip Removal Note.
1. Disconnect the lock rod at the handle assembly.
Item 3: Front Door Window Glass-to-Regulator Bolts Removal Note
CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet
removal process. If the holes become enlarged, the new rivets may become loose, resulting in a
clicking noise concern.
NOTE: Some vehicles may use rivets to attach the window.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
1. Lower the front door window glass as necessary to access bolts.
2. If removing the front door regulator assembly and motor, secure the front door glass in the full up
position with tape.
Item 4: Front Door Window Glass Removal Note
1. Pull glass out through the top inboard side of the door.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8938
Item 12: Glass Top Run Channel Assembly Removal Note
1. Remove the top glass run channel thorough the top opening of the front door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
REAR DOOR HANDLE
NOTE: RH side shown, LH side similar.
REMOVAL
1. Remove the rear door trim panel. 2. Position the watershield aside.
3. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Exterior Handle > System Information > Service and Repair > Page 8944
4. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service Precautions
Rear Door Panel: Service Precautions
CAUTION: To avoid damaging the trim panel, do not pull directly outward to carry out this step.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service Precautions > Page 8948
Rear Door Panel: Service and Repair
REAR DOOR TRIM PANEL
NOTE: LH side is shown, RH side is similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 6: Rear Door Trim Panel Removal Note
CAUTION: To avoid damaging the trim panel, do not pull directly outward to carry out this step.
1. Lift the door trim panel by pulling directly upward on the armrest to disengage the panel clips.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System
Information > Adjustments
Rear Door Striker: Adjustments
STRIKER ADJUSTMENT
1. Loosen the door latch striker bolts.
2. Adjust the door latch striker plate from side to side or up and down as necessary.
3. Tighten the door latch striker plate bolts.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
DOOR WINDOW GLASS - REAR
NOTE: RH side is shown. LH side is similar.
REMOVAL
1. Remove the rear door-mounted speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Page 8955
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Page 8956
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 4: Rear Door Glass-To-Regulator Bolts Removal Note
NOTE: Some vehicles may use rivets to attach the glass to the regulator.
1. Lower the rear door window glass as necessary to access bolt.
2. If removing the rear door glass regulator assembly and motor, secure the rear door glass in the
full up position with tape.
3. If removing the rear door glass regulator assembly and motor, remove the inside door handle but
do not disconnect the latch cable.
1 Remove the screw.
2 Disengage the inside door handle from the door.
Item 5: Rear Door Window Glass Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Page 8957
1. Pull the glass out through the top inboard side of the door.
Item 12: Rear Door Window Glass Top Run Removal Note
1. Remove the glass top run through the top opening of rear door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct >
07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Motor: Customer Interest Body - Rear Door Window Stuck In Up
Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct >
07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8966
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: >
07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Motor: All Technical Service Bulletins Body - Rear Door Window Stuck In Up
Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: >
07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8972
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct >
07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Regulator: Customer Interest Body - Rear Door Window Stuck In Up
Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct >
07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8981
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Regulator: All Technical Service Bulletins Body - Rear Door Window Stuck In
Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8987
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8988
Rear Door Window Regulator: By Symptom
Technical Service Bulletin # 07-20-5 Date: 071015
Body - Rear Door Window Stuck In Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8989
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8990
Disclaimer
Technical Service Bulletin # 07-20-5 Date: 071015
Body - Rear Door Window Stuck In Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8991
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8992
Disclaimer
Technical Service Bulletin # 07-20-5 Date: 071015
Body - Rear Door Window Stuck In Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8993
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: >
Page 8994
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > Page 8995
Rear Door Window Regulator: Service and Repair
WINDOW GLASS - REAR DOOR
NOTE: RH side is shown. LH side is similar.
REMOVAL
1. Remove the rear door-mounted speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > Page 8996
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > Page 8997
2. Remove the components in the order indicated in the illustration and table.
To remove individual components, only carry out the listed steps.
3. To install, reverse the removal procedure.
Item 4: Rear Door Glass-To-Regulator Bolts Removal Note
CAUTION: Make sure the hole in the glass bracket do not become enlarged during the rivet
removal process. If the hole become enlarged, the new rivets may become loose, resulting in a
clicking noise concern.
NOTE: Some vehicles may use rivets to attach the glass to the regulator.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
1. Lower the rear door window glass as necessary to access the bolts or rivets.
2. If removing the rear door glass regulator assembly and motor, secure the rear door glass in the
full up position with tape.
3. If removing the rear door glass regulator assembly and motor, remove the inside door handle but
do not disconnect the latch cable.
1 Remove the screw.
2 Disengage the inside door handle from the door.
Item 5: Rear Door Window Glass Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Technical Service Bulletins > Page 8998
1. Remove the applique on the rear door.
- Remove the screws.
2. Pull the glass out through the top inboard side of the door.
Item 10: Window Regulator Motor Removal Note.
1. Before removing the window regulator motor, secure the glass in the full up position with tape.
Item 12: Rear Door Window Glass Top Run Removal Note
1. Remove the glass top run through the top opening of rear door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair
Hood Latch: Service and Repair
HOOD LATCH
REMOVAL
1. To remove the individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair > Page 9003
2. Remove the components in the order indicated in the illustration and table.
Item 4: Hood Latch Removal Note
1. Disconnect the hood latch release cable.
Item 9: Hood Latch Release Cable Assembly Removal Note
1. Release the cable locators.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair > Page 9004
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Hood Latch Installation Note
1. When the hood latch is installed, the latch adjustment must be checked to make sure the latch
was installed and aligned correctly.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Locations > Page 9009
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
LIFTGATE WINDOW GLASS
REMOVAL
1. If installing a new liftgate window glass, remove the rear wiper motor.
2. Remove components in the order indicated in the illustration and table.
Item 1: Liftgate Trim Panel Removal Note
1. Position liftgate trim panel out of the way to access electrical connections and liftgate window
glass nuts.
Item 3: Liftgate Window Glass Struts Removal Note
1. CAUTION: Open and support the liftgate before removing the liftgate window glass struts.
Disconnect the liftgate window glass struts at the liftgate glass.
Item 5: Liftgate Window Glass Removal Note
1. CAUTION: Be sure not to scratch the applique located at the bottom of the glass.
With the help of an assistant, remove the liftgate window glass.
INSTALLATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair > Page 9014
1. NOTE: Transfer components as necessary.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator
View 151-43
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 9019
View 151-43
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 9022
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Liftgate Door Lock Switch
View 151-40
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Liftgate Door Lock Switch > Page 9027
View 151-42
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Liftgate Door Lock Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Liftgate Door Lock Switch > Page 9030
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Page 9031
Power Trunk / Liftgate Lock Switch: Testing and Inspection
Introduction To Component Testing
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Technical Service Bulletin # 04S20S5 Date: 050201
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Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS was activated 9/9/2004.
FSA VIN LIST ACTIVATED? Yes.
Available by 9/24/04.
Owner names and addresses available by 10/1/04.
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
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Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs in coordination with the
available supply of parts.
^ 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.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
^ If a related damage condition exists that you believe to be caused by the covered condition,
repair as necessary and submit a claim in accordance with the Warranty and Policy Manual
(Section 4).
^ Refer to Attachment IV for additional information.
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 that might prevent the
repair of the covered condition, call the Special Service Support Center.
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 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 an owners'
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 out the VIN for this recall.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 04S20 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
A rental vehicle is only authorized when:
^ A vehicle arrives with a shattered back glass and a new glass must be ordered.
^ A vehicle arrives with a broken hinge and the vehicle cannot be driven while parts are on order.
^ The back glass breaks during or shortly after kit installation.
^ Shop volume or service scheduling makes it impossible to store vehicles which require bracket
replacement for any of the specified cure times. It is anticipated that rental vehicles will only be
required in limited circumstances.
CLAIMS PREPARATION AND SUBMISSION
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^ 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.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
^ Refer to ACESII manual for claims preparation and submission information.
^ Anything other than the parts and labor operations specified in Attachment II must be on a related
damage claim.
Attachment II - Labor and Parts Information
[NEW!] LABOR ALLOWANCES
TOOL REQUIREMENTS
Rotunda Tool 501-040 is required to complete the ball stud bracket replacement. Each dealer will
be provided one applicator tool 501-040 at no charge. Tools have been mailed and should have
arrived at all dealerships by December 1, 2004. The tool shipping container will indicate "Enclosed
Adhesive Applicator Tool for Safety Recall 04S20.
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PARTS REQUIREMENTS / ORDERING INFORMATION [NEW!] Parts ordering restrictions have
been lifted (an announcement was sent via DOES II on 1/27/05). Parts will not be direct shipped for
this recall. Order your parts requirements through normal order processing channels.
ORDER INFORMATION
The DOR/COR for this program is 50330. This number identifies parts ordered for this Safety
Recall through the Special Service Support center.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
UPDATED FEBRUARY 2005
CERTAIN 2002 AND 2003 MODEL YEAR EXPLORER/MOUNTAINEER VEHICLES - LIFTGATE
GLASS BALL STUD BRACKET AND HINGE REPLACEMENT
[NEW] Based on information received from Dealership technicians, we have made improvements
to this Attachment III. A Fordstar Broadcast has been developed in conjunction with the release of
this Dealer Bulletin and is available for viewing. Please take the time to view that broadcast.
OVERVIEW This program involves replacing the liftgate glass ball stud brackets and liftgate glass
hinges on certain 2002 and 2003 Model Year Explorer and Mountaineer vehicles.
^ On early built 2002 model year vehicles, the liftgate glass ball stud brackets and liftgate glass
hinges require replacement.
^ On later built 2002 and all early 2003 model year vehicles, only the liftgate glass hinges require
replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001) were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be easily identified as not having ANY
adhesive between them and the glass. When removing ball
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stud bracket bolts, use extreme caution to turn the beauty bolt in the proper direction or the glass
may shatter under the pressure.
[NEW] SERVICE PRECAUTIONS
WARNING:
THE NEW HINGES AND PLASTIC HINGE GASKETS ARE IDENTIFIED AS EITHER
RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE OR DRIVER SIDE). IF INSTALLED ON THE
WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR
IDENTIFICATION DETAILS.
NOTE:
On some hinges the casting marks are very light and difficult to read. Look closely to make sure
each bracket is properly identified.
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER WILL RESULT IN
SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number - N621 926-S36)
nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they do not go on, use new 6-mm nuts.
INSPECTION
To properly identify the vehicle and decide which repairs to perform, inspect for the presence of
liftgate glass beauty bolts.
^ Early 2002 models use ball stud brackets that are secured with beauty bolts, which pass through
the glass (the head of the bolt is visible on the outside of the glass) and are bonded to the glass
about 150 mm (6 inches) from the top of the glass. See Figure 2. If beauty bolts are present, both
the liftgate ball stud brackets and hinges will be replaced. Perform BOTH the Liftgate Glass Hinge
Replacement and the Ball Stud Bracket Replacement. Begin your repairs with LIFTGATE GLASS
HINGE REPLACEMENT.
^ Later built 2002 and 2003 model year vehicles use revised ball stud brackets which are not
secured with beauty bolts. If beauty bolts are not present, only the hinges will be replaced. Perform
only the LIFTGATE GLASS HINGE REPLACEMENT.
LIFTGATE GLASS HINGE REPLACEMENT - ALL AFFECTED VEHICLES
NOTE:
The Hinge Replacement procedure must be completed prior to the Ball Stud Bracket procedure.
REMOVAL
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WARNING:
BE SURE TO USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS SAFETY GLASSES AND
EQUIPMENT THAT WILL PROTECT AGAINST PERSONAL INJURY IN THE EVENT OF GLASS
BREAKAGE.
CAUTION:
Do not use power tools when working on the glass.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. Disconnect the liftgate glass support struts from both ends and remove from the vehicle.
3. Remove the jack stand and carefully close the glass making sure the striker is engaged in the
latch.
[NEW]4. CAUTION: The location of the original glass hinges must be clearly marked on the glass
to make sure the new hinges are accurately positioned and that the glass is properly aligned.
Failure to properly align the new hinges to these marks may result in glass shattering.
Using a grease pencil, a non-permanent marker or tape, outline the entire perimeter of the original
hinges to mark their exact location on the glass. See Figure 3.
5. Open the full liftgate.
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6. Position the upper part of the liftgate trim panel away from the liftgate to gain access to the hinge
fasteners. See Figure 4.
7. Using a magnetic socket or tool, remove one (1) liftgate glass hinge-to-body nut, then the
hinge-to-glass bolt and remove one (1) hinge from the vehicle. Retain the plastic spacers from the
hinge-to-glass bolts for use with the new bolts. See Figure 5.
[NEW]8. Clean the glass, particularly at the edge around the hole, then inspect the edge of the hole
in the glass to see if it is chipped or cracked. If the glass is chipped or cracked, the glass must be
replaced. Discontinue this service in lieu of liftgate glass replacement.
INSTALLATION
[NEW] SERVICE PRECAUTIONS
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WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
CLEANED AND TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER
WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
WARNING:
THE NEW HINGES ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER
SIDE OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS
MAY SHATTER. SEE FIGURE 1 FOR IDENTIFICATION DETAILS.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
[NEW]CAUTION:
Be sure the glass and plastic hinge gaskets are very clean and contain no grit, dirt, sand or any
other foreign matter prior to installation. Even the smallest bit of any hard material captured
between the plastic gasket and the glass may cause the glass to shatter.
[NEW]NOTE:
When installing the plastic gasket onto the new hinge, be sure it sits flush onto the hinge surface.
Please note that some gaskets are known to fit very tightly around the threaded boss which may
make gasket installation difficult. Be sure the gasket is fully seated before installing the hinge.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number- N621926-S36) nuts
must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they
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do not go on, use new 6-mm nuts.
[NEW]1. WARNING: WHEN INSTALLING THE HINGE ASSEMBLY TO THE GLASS, BE SURE
THE SHOULDERS OF BOLTS, SPACERS AND GASKETS ARE PROPERLY ALIGNED INSIDE
THE HOLE IN THE GLASS. DO NOT ALLOW THEM TO SIT ON OR BE PROPPED UP ON THE
EDGE OF THE GLASS OR THE GLASS MAY SHATTER WHEN THE BOLTS ARE TIGHTENED
TO SPECIFICATION.
Transfer the plastic spacer from the old hinge-to-glass bolt onto the new bolt, then apply Thread
lock 262 (Motorcraft TA-26, red high strength) to the hinge-to-glass bolt threads even though it
already has lock tite, then position the hinge onto the vehicle.
[NEW]CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
2. Install the hinge bolt and nut FINGER TIGHT ONLY at this time.
3. Tighten the hinge BOLT FIRST to 8 Nm (71 lb-in).
4. Tighten the hinge NUT SECOND to 11 Nm (8 lb-ft or 97 lb-in).
5. Repeat Removal Steps 7 and 8 and Installation Steps 1 through 4 for the other hinge.
6. Reposition and secure the liftgate trim panel.
7. Close the liftgate.
NOTE:
If the beauty bolts are present (See INSPECTION), proceed to the Liftgate Ball Stud Bracket
Replacement procedure. If the beauty bolts are NOT present, complete Steps 8 and 9 and release
the vehicle.
8. Install the liftgate glass support struts.
9. Remove the jack stand and close the liftgate glass.
LIFTGATE GLASS BALL STUD BRACKET REPLACEMENT - EARLY 2002 MODEL YEAR
VEHICLES ONLY (VEHICLES WITH BEAUTY BOLTS)
CAUTION:
Do not use powertools when working on glass.
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NOTE:
The new brackets are marked with a stamping, L or R followed by a number. They are NOT
interchangeable. The L is for the driver side of the glass and has left-hand threads. The R is for the
passenger side of the glass and has right-hand threads. The number can be ignored. See Figure 7.
CAUTION:
Due to the extremely short working time of the adhesive (less than one [1] minute), it is imperative
that only one (1) bracket be replaced at a time. Failure to specifically follow these instructions will
result in a ruined backglass or failure of the adhesive to bond properly to the glass.
NOTE:
Before the installation of the liftgate glass ball stud bracket, make sure that the interior surface of
the glass is clean and free of any visible moisture.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. WARNING: PERSONAL PROTECTIVE EQUIPMENT (SAFETY GLASSES) IS REQUIRED
WHEN WORKING WITH GLASS OR INJURY MAY OCCUR IN THE EVENT OF GLASS
BREAKAGE.
NOTE:
If you encounter ball stud brackets that do not twist off easily after removing the beauty bolt, it may
be due to an alternative adhesive that was applied as an interim repair. If the brackets cannot be
removed, the glass must be replaced. Discontinue this service in lieu of liftgate glass replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001), were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be identified as not having ANY
adhesive between them and the glass. When removing ball stud bracket bolts, use extreme caution
to turn the beauty bolt in the proper direction or the glass may shatter under the pressure.
Remove the bracket from the glass by first removing the beauty bolt using a T-30 Torx bit, then
twist the bracket off the glass using a 17-mm box-end wrench.
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NOTE:
With the liftgate glass open, be sure to properly orient the new brackets with the ball stud pointing
upward and outward. See Figure 8.
3. Hold the new bracket in position on the glass with the ball stud pointing UP and OUT (with the
liftgate glass open). Mark the area around the bracket using masking tape or vinyl tape. Leave a
space approximately 7 mm (1/4 in) between the edge of the bracket and the tape. The taped-off
area should be approximately 57-mm (2-1/4 in) wide and 89-mm (3-1/2 in) high. See Figure 9 for
proper placement and dimensions. After the tape is applied, remove the bracket. The tape will be
used as an alignment guide, therefore, keep the tape in place until completing the final bracket
alignment.
4. CAUTION: Care should be taken to avoid damage to the frosted coating on the glass.
Completely remove all existing adhesive from the glass using a sharp razor blade scraper. Clean
the area of any residual adhesive using the supplied Scotch Brite(R) scuff pad. See Figure 10.
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[NEW] 5. Clean the area using the supplied alcohol wipe and allow it to dry completely, ensuring no
moisture is present. Then, inspect the edge of the hole for any chips or cracks. If the glass is
chipped or cracked, the glass must be replaced. Discontinue this service in lieu of liftgate glass
replacement.
CAUTION:
This primer requires a minimum of fifteen (15) minutes dry time before adhesive can be applied.
Failure to wait the necessary fifteen (15) minutes will lead to the failure of the adhesive.
6. Using one of the supplied dauber brushes, neatly apply a thin coat of Chemlok 144(R) primer to
the taped-off area, then carefully remove the tape. Allow the primer to dry for at least fifteen (15)
minutes, ensuring no moisture is present before installing the new brackets.
While waiting for the primer to dry, remove the original bracket and prepare the surface 1 on the
opposite side of the glass (repeat Steps 2 through 7).
7. NOTE: When scuffing the new bracket, use light pressure to avoid exposing bare metal.
Using the Scotch Brite(R) scuff pad, carefully scuff the backside of both new brackets so that the
surface no longer has a shiny appearance, then wipe it clean with one of the supplied alcohol
wipes.
[NEW]8. CAUTION: Be sure the glass and plastic washers are very clean and contain no grit, dirt,
sand or any other foreign matter prior to installation. Even the smallest bit of any hard material
captured between the plastic washer and the glass may cause the glass to shatter.
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Install the plastic spacer (with locating tab) and rubber washer onto the new brackets as shown in
Figure 11. Also, place a plastic washer onto the beauty bolt with the collar toward the glass.
9. CAUTION: Failure to prepare the adhesive cartridge and mixer tip as described may cause
insufficient mixing of the product. This may lead to insufficient bonding of the bracket(s) to the
glass.
Assemble the adhesive cartridge and application tool and purge the cartridge as follows:
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A) Trim approximately 13 mm (0.5 in) off the top of both mixer tips, down to the last ring. See
Figure 12.
B) Install the Fusor(R) # 143 adhesive cartridge into the application tool (No. 501-040).
C) Dispense a small amount of adhesive from the cartridge onto a piece of scrap cardboard to level
the plungers and to ensure an even flow of both components.
D) Install one (1) mixer tip onto the cartridge and dispense a 75-mm (3-in) bead of the adhesive
onto a piece of scrap cardboard (until the product is evenly mixed and the color is consistent).
NOTE:
Due to the working times involved and the necessity of changing mixing tips on the application tool,
these instructions are written to perform installation of the left-side bracket first, then the right-side
bracket. Please review these instructions and understand the process before proceeding with
adhesive application and bracket installation.
10. CAUTION: The adhesive used to install the liftgate glass ball stud brackets will require at least
two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder
environment before two hours has elapsed, cure time will increase substantially before the liftgate
glass struts can be reattached. The following guidelines must be followed in order to ensure
properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
NOTE:
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Once the adhesive mixes. you will have less than one (1) minute to install the new bracket before
the adhesive begins to set. The adhesive will require at least two (2) hours at 70°F or higher to cure
before the liftgate glass support struts can be attached.
NOTE:
Keep the used mixer tip attached to the cartridge after use.
After the primer has dried for fifteen (15) minutes, apply three (3) large beads (9-10 mm in
diameter) of adhesive to the backside of the new left-side bracket. See Figure 13.
11. NOTE: Left side bolts and brackets have left-hand threads.
NOTE:
Once the bracket is in position, DO NOT lift it from the glass. You may twist or turn the bracket
slightly, but it must remain in contact with the glass to prevent the formation of air bubbles in the
adhesive.
With the correct left-hand thread beauty bolt and plastic washer ready in one hand, position the
new left-side bracket onto the glass and align it with the beauty bolt hole and parallel with the edge
of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
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While holding the bracket nut with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
12. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
13. NOTE: Be sure to use a new mixer tip for each bracket.
Install a new trimmed mixer tip onto the adhesive cartridge, then dispense a 75-mm (3-in) bead of
adhesive onto a piece of scrap cardboard to ensure the product is evenly mixed in the tip and is
ready for application.
14. Apply three (3) large beads (9-10 mm in diameter) of adhesive to the backside of the new
right-side bracket. See Figure 13.
15. With the correct right-hand thread beauty bolt and plastic washer ready in one hand position
the new right-side bracket onto the glass and align it with the beauty bolt hole and parallel with the
edge of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
While holding the bracket with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
16. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
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^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
17. Remove the jack stand, carefully close the glass making sure the striker is engaged in the
latch, and allow the adhesive to cure as indicated in the caution above.
18. After the adhesive has cured as required per the caution above, reattach the liftgate glass
support struts before releasing the vehicle to the customer.
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Hinge: > NHTSA04V442000 > Sep > 04
> Recall 04V244000: Liftgate Glass Strut/Hinge Defect
Trunk / Liftgate Hinge: Recalls Recall 04V244000: Liftgate Glass Strut/Hinge Defect
Make / Models : Model/Build Years: Ford / Explorer 2002-2003 Ford / Mountaineer 2002-2003
MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V442000 Recall
Date : SEP 09, 2004
COMPONENT: Structure: Body: Hatchback/Liftgate: Hinge and Attachments
Potential Number Of Units Affected : 955732
SUMMARY: On certain sport utility vehicles, the liftgate glass strut may become disengaged or the
hinge may fracture allowing the glass to fall and possibly break.
CONSEQUENCE: If the hinge should fracture, there is a potential for the glass to fall and ultimately
break and personal injuries could occur.
REMEDY: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the
vehicles built from August 1, 2000 through March 3, 2002, The dealers will replace the hinges and
liftgate strut bracket. On vehicles built from March 3, 2002 through June 23, 2003, The Dealers will
only replace the hinges. The recall began on September 30, 2004. Owners should contact Ford at
1-800-392-3673.
NOTES: Ford Recall NO. 04S20. Customers can also contact The National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
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> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge
Technical Service Bulletin # 04S20S5 Date: 050201
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> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9080
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> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9081
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> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9082
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS was activated 9/9/2004.
FSA VIN LIST ACTIVATED? Yes.
Available by 9/24/04.
Owner names and addresses available by 10/1/04.
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
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> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9083
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs in coordination with the
available supply of parts.
^ 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.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
^ If a related damage condition exists that you believe to be caused by the covered condition,
repair as necessary and submit a claim in accordance with the Warranty and Policy Manual
(Section 4).
^ Refer to Attachment IV for additional information.
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 that might prevent the
repair of the covered condition, call the Special Service Support Center.
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 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 an owners'
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 out the VIN for this recall.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 04S20 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
A rental vehicle is only authorized when:
^ A vehicle arrives with a shattered back glass and a new glass must be ordered.
^ A vehicle arrives with a broken hinge and the vehicle cannot be driven while parts are on order.
^ The back glass breaks during or shortly after kit installation.
^ Shop volume or service scheduling makes it impossible to store vehicles which require bracket
replacement for any of the specified cure times. It is anticipated that rental vehicles will only be
required in limited circumstances.
CLAIMS PREPARATION AND SUBMISSION
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^ 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.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
^ Refer to ACESII manual for claims preparation and submission information.
^ Anything other than the parts and labor operations specified in Attachment II must be on a related
damage claim.
Attachment II - Labor and Parts Information
[NEW!] LABOR ALLOWANCES
TOOL REQUIREMENTS
Rotunda Tool 501-040 is required to complete the ball stud bracket replacement. Each dealer will
be provided one applicator tool 501-040 at no charge. Tools have been mailed and should have
arrived at all dealerships by December 1, 2004. The tool shipping container will indicate "Enclosed
Adhesive Applicator Tool for Safety Recall 04S20.
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PARTS REQUIREMENTS / ORDERING INFORMATION [NEW!] Parts ordering restrictions have
been lifted (an announcement was sent via DOES II on 1/27/05). Parts will not be direct shipped for
this recall. Order your parts requirements through normal order processing channels.
ORDER INFORMATION
The DOR/COR for this program is 50330. This number identifies parts ordered for this Safety
Recall through the Special Service Support center.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
UPDATED FEBRUARY 2005
CERTAIN 2002 AND 2003 MODEL YEAR EXPLORER/MOUNTAINEER VEHICLES - LIFTGATE
GLASS BALL STUD BRACKET AND HINGE REPLACEMENT
[NEW] Based on information received from Dealership technicians, we have made improvements
to this Attachment III. A Fordstar Broadcast has been developed in conjunction with the release of
this Dealer Bulletin and is available for viewing. Please take the time to view that broadcast.
OVERVIEW This program involves replacing the liftgate glass ball stud brackets and liftgate glass
hinges on certain 2002 and 2003 Model Year Explorer and Mountaineer vehicles.
^ On early built 2002 model year vehicles, the liftgate glass ball stud brackets and liftgate glass
hinges require replacement.
^ On later built 2002 and all early 2003 model year vehicles, only the liftgate glass hinges require
replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001) were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be easily identified as not having ANY
adhesive between them and the glass. When removing ball
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stud bracket bolts, use extreme caution to turn the beauty bolt in the proper direction or the glass
may shatter under the pressure.
[NEW] SERVICE PRECAUTIONS
WARNING:
THE NEW HINGES AND PLASTIC HINGE GASKETS ARE IDENTIFIED AS EITHER
RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE OR DRIVER SIDE). IF INSTALLED ON THE
WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR
IDENTIFICATION DETAILS.
NOTE:
On some hinges the casting marks are very light and difficult to read. Look closely to make sure
each bracket is properly identified.
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER WILL RESULT IN
SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number - N621 926-S36)
nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they do not go on, use new 6-mm nuts.
INSPECTION
To properly identify the vehicle and decide which repairs to perform, inspect for the presence of
liftgate glass beauty bolts.
^ Early 2002 models use ball stud brackets that are secured with beauty bolts, which pass through
the glass (the head of the bolt is visible on the outside of the glass) and are bonded to the glass
about 150 mm (6 inches) from the top of the glass. See Figure 2. If beauty bolts are present, both
the liftgate ball stud brackets and hinges will be replaced. Perform BOTH the Liftgate Glass Hinge
Replacement and the Ball Stud Bracket Replacement. Begin your repairs with LIFTGATE GLASS
HINGE REPLACEMENT.
^ Later built 2002 and 2003 model year vehicles use revised ball stud brackets which are not
secured with beauty bolts. If beauty bolts are not present, only the hinges will be replaced. Perform
only the LIFTGATE GLASS HINGE REPLACEMENT.
LIFTGATE GLASS HINGE REPLACEMENT - ALL AFFECTED VEHICLES
NOTE:
The Hinge Replacement procedure must be completed prior to the Ball Stud Bracket procedure.
REMOVAL
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WARNING:
BE SURE TO USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS SAFETY GLASSES AND
EQUIPMENT THAT WILL PROTECT AGAINST PERSONAL INJURY IN THE EVENT OF GLASS
BREAKAGE.
CAUTION:
Do not use power tools when working on the glass.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. Disconnect the liftgate glass support struts from both ends and remove from the vehicle.
3. Remove the jack stand and carefully close the glass making sure the striker is engaged in the
latch.
[NEW]4. CAUTION: The location of the original glass hinges must be clearly marked on the glass
to make sure the new hinges are accurately positioned and that the glass is properly aligned.
Failure to properly align the new hinges to these marks may result in glass shattering.
Using a grease pencil, a non-permanent marker or tape, outline the entire perimeter of the original
hinges to mark their exact location on the glass. See Figure 3.
5. Open the full liftgate.
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6. Position the upper part of the liftgate trim panel away from the liftgate to gain access to the hinge
fasteners. See Figure 4.
7. Using a magnetic socket or tool, remove one (1) liftgate glass hinge-to-body nut, then the
hinge-to-glass bolt and remove one (1) hinge from the vehicle. Retain the plastic spacers from the
hinge-to-glass bolts for use with the new bolts. See Figure 5.
[NEW]8. Clean the glass, particularly at the edge around the hole, then inspect the edge of the hole
in the glass to see if it is chipped or cracked. If the glass is chipped or cracked, the glass must be
replaced. Discontinue this service in lieu of liftgate glass replacement.
INSTALLATION
[NEW] SERVICE PRECAUTIONS
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WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
CLEANED AND TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER
WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
WARNING:
THE NEW HINGES ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER
SIDE OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS
MAY SHATTER. SEE FIGURE 1 FOR IDENTIFICATION DETAILS.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
[NEW]CAUTION:
Be sure the glass and plastic hinge gaskets are very clean and contain no grit, dirt, sand or any
other foreign matter prior to installation. Even the smallest bit of any hard material captured
between the plastic gasket and the glass may cause the glass to shatter.
[NEW]NOTE:
When installing the plastic gasket onto the new hinge, be sure it sits flush onto the hinge surface.
Please note that some gaskets are known to fit very tightly around the threaded boss which may
make gasket installation difficult. Be sure the gasket is fully seated before installing the hinge.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number- N621926-S36) nuts
must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they
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do not go on, use new 6-mm nuts.
[NEW]1. WARNING: WHEN INSTALLING THE HINGE ASSEMBLY TO THE GLASS, BE SURE
THE SHOULDERS OF BOLTS, SPACERS AND GASKETS ARE PROPERLY ALIGNED INSIDE
THE HOLE IN THE GLASS. DO NOT ALLOW THEM TO SIT ON OR BE PROPPED UP ON THE
EDGE OF THE GLASS OR THE GLASS MAY SHATTER WHEN THE BOLTS ARE TIGHTENED
TO SPECIFICATION.
Transfer the plastic spacer from the old hinge-to-glass bolt onto the new bolt, then apply Thread
lock 262 (Motorcraft TA-26, red high strength) to the hinge-to-glass bolt threads even though it
already has lock tite, then position the hinge onto the vehicle.
[NEW]CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
2. Install the hinge bolt and nut FINGER TIGHT ONLY at this time.
3. Tighten the hinge BOLT FIRST to 8 Nm (71 lb-in).
4. Tighten the hinge NUT SECOND to 11 Nm (8 lb-ft or 97 lb-in).
5. Repeat Removal Steps 7 and 8 and Installation Steps 1 through 4 for the other hinge.
6. Reposition and secure the liftgate trim panel.
7. Close the liftgate.
NOTE:
If the beauty bolts are present (See INSPECTION), proceed to the Liftgate Ball Stud Bracket
Replacement procedure. If the beauty bolts are NOT present, complete Steps 8 and 9 and release
the vehicle.
8. Install the liftgate glass support struts.
9. Remove the jack stand and close the liftgate glass.
LIFTGATE GLASS BALL STUD BRACKET REPLACEMENT - EARLY 2002 MODEL YEAR
VEHICLES ONLY (VEHICLES WITH BEAUTY BOLTS)
CAUTION:
Do not use powertools when working on glass.
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> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9091
NOTE:
The new brackets are marked with a stamping, L or R followed by a number. They are NOT
interchangeable. The L is for the driver side of the glass and has left-hand threads. The R is for the
passenger side of the glass and has right-hand threads. The number can be ignored. See Figure 7.
CAUTION:
Due to the extremely short working time of the adhesive (less than one [1] minute), it is imperative
that only one (1) bracket be replaced at a time. Failure to specifically follow these instructions will
result in a ruined backglass or failure of the adhesive to bond properly to the glass.
NOTE:
Before the installation of the liftgate glass ball stud bracket, make sure that the interior surface of
the glass is clean and free of any visible moisture.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. WARNING: PERSONAL PROTECTIVE EQUIPMENT (SAFETY GLASSES) IS REQUIRED
WHEN WORKING WITH GLASS OR INJURY MAY OCCUR IN THE EVENT OF GLASS
BREAKAGE.
NOTE:
If you encounter ball stud brackets that do not twist off easily after removing the beauty bolt, it may
be due to an alternative adhesive that was applied as an interim repair. If the brackets cannot be
removed, the glass must be replaced. Discontinue this service in lieu of liftgate glass replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001), were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be identified as not having ANY
adhesive between them and the glass. When removing ball stud bracket bolts, use extreme caution
to turn the beauty bolt in the proper direction or the glass may shatter under the pressure.
Remove the bracket from the glass by first removing the beauty bolt using a T-30 Torx bit, then
twist the bracket off the glass using a 17-mm box-end wrench.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9092
NOTE:
With the liftgate glass open, be sure to properly orient the new brackets with the ball stud pointing
upward and outward. See Figure 8.
3. Hold the new bracket in position on the glass with the ball stud pointing UP and OUT (with the
liftgate glass open). Mark the area around the bracket using masking tape or vinyl tape. Leave a
space approximately 7 mm (1/4 in) between the edge of the bracket and the tape. The taped-off
area should be approximately 57-mm (2-1/4 in) wide and 89-mm (3-1/2 in) high. See Figure 9 for
proper placement and dimensions. After the tape is applied, remove the bracket. The tape will be
used as an alignment guide, therefore, keep the tape in place until completing the final bracket
alignment.
4. CAUTION: Care should be taken to avoid damage to the frosted coating on the glass.
Completely remove all existing adhesive from the glass using a sharp razor blade scraper. Clean
the area of any residual adhesive using the supplied Scotch Brite(R) scuff pad. See Figure 10.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9093
[NEW] 5. Clean the area using the supplied alcohol wipe and allow it to dry completely, ensuring no
moisture is present. Then, inspect the edge of the hole for any chips or cracks. If the glass is
chipped or cracked, the glass must be replaced. Discontinue this service in lieu of liftgate glass
replacement.
CAUTION:
This primer requires a minimum of fifteen (15) minutes dry time before adhesive can be applied.
Failure to wait the necessary fifteen (15) minutes will lead to the failure of the adhesive.
6. Using one of the supplied dauber brushes, neatly apply a thin coat of Chemlok 144(R) primer to
the taped-off area, then carefully remove the tape. Allow the primer to dry for at least fifteen (15)
minutes, ensuring no moisture is present before installing the new brackets.
While waiting for the primer to dry, remove the original bracket and prepare the surface 1 on the
opposite side of the glass (repeat Steps 2 through 7).
7. NOTE: When scuffing the new bracket, use light pressure to avoid exposing bare metal.
Using the Scotch Brite(R) scuff pad, carefully scuff the backside of both new brackets so that the
surface no longer has a shiny appearance, then wipe it clean with one of the supplied alcohol
wipes.
[NEW]8. CAUTION: Be sure the glass and plastic washers are very clean and contain no grit, dirt,
sand or any other foreign matter prior to installation. Even the smallest bit of any hard material
captured between the plastic washer and the glass may cause the glass to shatter.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9094
Install the plastic spacer (with locating tab) and rubber washer onto the new brackets as shown in
Figure 11. Also, place a plastic washer onto the beauty bolt with the collar toward the glass.
9. CAUTION: Failure to prepare the adhesive cartridge and mixer tip as described may cause
insufficient mixing of the product. This may lead to insufficient bonding of the bracket(s) to the
glass.
Assemble the adhesive cartridge and application tool and purge the cartridge as follows:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9095
A) Trim approximately 13 mm (0.5 in) off the top of both mixer tips, down to the last ring. See
Figure 12.
B) Install the Fusor(R) # 143 adhesive cartridge into the application tool (No. 501-040).
C) Dispense a small amount of adhesive from the cartridge onto a piece of scrap cardboard to level
the plungers and to ensure an even flow of both components.
D) Install one (1) mixer tip onto the cartridge and dispense a 75-mm (3-in) bead of the adhesive
onto a piece of scrap cardboard (until the product is evenly mixed and the color is consistent).
NOTE:
Due to the working times involved and the necessity of changing mixing tips on the application tool,
these instructions are written to perform installation of the left-side bracket first, then the right-side
bracket. Please review these instructions and understand the process before proceeding with
adhesive application and bracket installation.
10. CAUTION: The adhesive used to install the liftgate glass ball stud brackets will require at least
two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder
environment before two hours has elapsed, cure time will increase substantially before the liftgate
glass struts can be reattached. The following guidelines must be followed in order to ensure
properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
NOTE:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9096
Once the adhesive mixes. you will have less than one (1) minute to install the new bracket before
the adhesive begins to set. The adhesive will require at least two (2) hours at 70°F or higher to cure
before the liftgate glass support struts can be attached.
NOTE:
Keep the used mixer tip attached to the cartridge after use.
After the primer has dried for fifteen (15) minutes, apply three (3) large beads (9-10 mm in
diameter) of adhesive to the backside of the new left-side bracket. See Figure 13.
11. NOTE: Left side bolts and brackets have left-hand threads.
NOTE:
Once the bracket is in position, DO NOT lift it from the glass. You may twist or turn the bracket
slightly, but it must remain in contact with the glass to prevent the formation of air bubbles in the
adhesive.
With the correct left-hand thread beauty bolt and plastic washer ready in one hand, position the
new left-side bracket onto the glass and align it with the beauty bolt hole and parallel with the edge
of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9097
While holding the bracket nut with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
12. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
13. NOTE: Be sure to use a new mixer tip for each bracket.
Install a new trimmed mixer tip onto the adhesive cartridge, then dispense a 75-mm (3-in) bead of
adhesive onto a piece of scrap cardboard to ensure the product is evenly mixed in the tip and is
ready for application.
14. Apply three (3) large beads (9-10 mm in diameter) of adhesive to the backside of the new
right-side bracket. See Figure 13.
15. With the correct right-hand thread beauty bolt and plastic washer ready in one hand position
the new right-side bracket onto the glass and align it with the beauty bolt hole and parallel with the
edge of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
While holding the bracket with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
16. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9098
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
17. Remove the jack stand, carefully close the glass making sure the striker is engaged in the
latch, and allow the adhesive to cure as indicated in the caution above.
18. After the adhesive has cured as required per the caution above, reattach the liftgate glass
support struts before releasing the vehicle to the customer.
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Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9099
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9100
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9101
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9102
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9103
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9104
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9105
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9106
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9107
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9108
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: > 04S20S5
> Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9109
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Hinge: >
NHTSA04V442000 > Sep > 04 > Recall 04V244000: Liftgate Glass Strut/Hinge Defect
Trunk / Liftgate Hinge: All Technical Service Bulletins Recall 04V244000: Liftgate Glass Strut/Hinge
Defect
Make / Models : Model/Build Years: Ford / Explorer 2002-2003 Ford / Mountaineer 2002-2003
MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V442000 Recall
Date : SEP 09, 2004
COMPONENT: Structure: Body: Hatchback/Liftgate: Hinge and Attachments
Potential Number Of Units Affected : 955732
SUMMARY: On certain sport utility vehicles, the liftgate glass strut may become disengaged or the
hinge may fracture allowing the glass to fall and possibly break.
CONSEQUENCE: If the hinge should fracture, there is a potential for the glass to fall and ultimately
break and personal injuries could occur.
REMEDY: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the
vehicles built from August 1, 2000 through March 3, 2002, The dealers will replace the hinges and
liftgate strut bracket. On vehicles built from March 3, 2002 through June 23, 2003, The Dealers will
only replace the hinges. The recall began on September 30, 2004. Owners should contact Ford at
1-800-392-3673.
NOTES: Ford Recall NO. 04S20. Customers can also contact The National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
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Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Handle: > 05-9-5 > May > 05
> Body - License Plate Shield Cracked/Broken
Trunk / Liftgate Handle: Customer Interest Body - License Plate Shield Cracked/Broken
TSB 05-9-5
05/16/05
LICENSE PLATE SHIELD CRACKS OR BREAKS - VEHICLES BUILT BEFORE 10/14/2004 WITH
XLS TRIM
FORD: 2003-2005 Explorer
ISSUE Some 2003-2005 Explorer 4dr vehicles built before 10/14/2004 and with XLS trim, may
exhibit the license plate shield cracking or breaking in cold temperatures. This may be due to the
liftgate release handle coming in contact with the shield during use.
ACTION
If the license plate shield is damaged, replace the shield and the rear liftgate release handle.
SERVICE PROCEDURE
1. Replace the liftgate release handle per Section 501-14 of the Workshop Manual.
LICENSE PLATE SHIELD REPLACEMENT
1. Remove the four (4) attachment bolts and remove the license plate shield (Figure 1).
2. Install the replacement shield and torque the bolts to 108 lb-in (12 N.m).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050905A 2003-2005 Explorer 4 Door 0.4 Hr.
Replace The Rear Liftgate Release Handle And License Plate Shield (Do Not Use With 46404B,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Handle: > 05-9-5 > May > 05
> Body - License Plate Shield Cracked/Broken > Page 9122
46404B10, P42D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7843400 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Handle: > 05-9-5
> May > 05 > Body - License Plate Shield Cracked/Broken
Trunk / Liftgate Handle: All Technical Service Bulletins Body - License Plate Shield
Cracked/Broken
TSB 05-9-5
05/16/05
LICENSE PLATE SHIELD CRACKS OR BREAKS - VEHICLES BUILT BEFORE 10/14/2004 WITH
XLS TRIM
FORD: 2003-2005 Explorer
ISSUE Some 2003-2005 Explorer 4dr vehicles built before 10/14/2004 and with XLS trim, may
exhibit the license plate shield cracking or breaking in cold temperatures. This may be due to the
liftgate release handle coming in contact with the shield during use.
ACTION
If the license plate shield is damaged, replace the shield and the rear liftgate release handle.
SERVICE PROCEDURE
1. Replace the liftgate release handle per Section 501-14 of the Workshop Manual.
LICENSE PLATE SHIELD REPLACEMENT
1. Remove the four (4) attachment bolts and remove the license plate shield (Figure 1).
2. Install the replacement shield and torque the bolts to 108 lb-in (12 N.m).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050905A 2003-2005 Explorer 4 Door 0.4 Hr.
Replace The Rear Liftgate Release Handle And License Plate Shield (Do Not Use With 46404B,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Handle: > 05-9-5
> May > 05 > Body - License Plate Shield Cracked/Broken > Page 9128
46404B10, P42D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7843400 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > Page 9129
Trunk / Liftgate Handle: Service and Repair
LIFTGATE RELEASE HANDLE
REMOVAL
1. Remove the liftgate trim panel. 2. Position the watershield aside.
3. To remove individual components, only carry out the listed steps.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > Page 9130
Part 1
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Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Technical Service Bulletins > Page 9131
Part 2
4. Remove the components in the order indicated in the illustration and table.
Item 15: Rivet Removal Note
1. Remove the four bolts and the license plate lamp shield. 2. Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch: > 05-13-6 > Jul > 05 >
Body - Back Glass Hard to Close/Door Ajar Lamp ON
Trunk / Liftgate Latch: Customer Interest Body - Back Glass Hard to Close/Door Ajar Lamp ON
TSB 05-13-6
07/11/05
BACKGLASS DIFFICULT TO CLOSE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Lincoln Aviator vehicles may exhibit
a difficult to close backglass and an intermittent door ajar lamp. This condition may be due to a
stack up tolerance between the backglass to body dimensions and latch position.
ACTION When attempting to determine root cause, ensure the glass is being closed with enough
force to fully latch. Allowing the glass to fall on its own is not sufficient force for proper closure. If
normal diagnostics do not lead to a root cause perform the following:
^ For vehicles built before 2/15/2005, replace the latch assembly and adjust rearward.
^ For vehicles built 2/15/2005 or later, only adjust the existing latch rearward.
Refer to Workshop Manual Section 501-14.
NOTE
IF NECESSARY, THE HOLES IN THE LATCH ASSEMBLY CAN BE ENLARGED USING A 23/64
INCH (9 MM) DRILL BIT FOR ADDED ADJUSTMENT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051306A 2002-2005 0.6 Hr.
Explorer/Mountaineer 2003-2005 Aviator: Replace The Liftgate Glass Latch (Includes Time To
Install New Latch, If Necessary Remove The Latch Enlarge Holes For Added Adjustment) (Do Not
Use With 46404B, 46404B4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7840860 42
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Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch: > 05-13-6 > Jul > 05 >
Body - Back Glass Hard to Close/Door Ajar Lamp ON > Page 9140
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 05-13-6 >
Jul > 05 > Body - Back Glass Hard to Close/Door Ajar Lamp ON
Trunk / Liftgate Latch: All Technical Service Bulletins Body - Back Glass Hard to Close/Door Ajar
Lamp ON
TSB 05-13-6
07/11/05
BACKGLASS DIFFICULT TO CLOSE
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer/Mountaineer and 2003-2005 Lincoln Aviator vehicles may exhibit
a difficult to close backglass and an intermittent door ajar lamp. This condition may be due to a
stack up tolerance between the backglass to body dimensions and latch position.
ACTION When attempting to determine root cause, ensure the glass is being closed with enough
force to fully latch. Allowing the glass to fall on its own is not sufficient force for proper closure. If
normal diagnostics do not lead to a root cause perform the following:
^ For vehicles built before 2/15/2005, replace the latch assembly and adjust rearward.
^ For vehicles built 2/15/2005 or later, only adjust the existing latch rearward.
Refer to Workshop Manual Section 501-14.
NOTE
IF NECESSARY, THE HOLES IN THE LATCH ASSEMBLY CAN BE ENLARGED USING A 23/64
INCH (9 MM) DRILL BIT FOR ADDED ADJUSTMENT.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051306A 2002-2005 0.6 Hr.
Explorer/Mountaineer 2003-2005 Aviator: Replace The Liftgate Glass Latch (Includes Time To
Install New Latch, If Necessary Remove The Latch Enlarge Holes For Added Adjustment) (Do Not
Use With 46404B, 46404B4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7840860 42
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: > 05-13-6 >
Jul > 05 > Body - Back Glass Hard to Close/Door Ajar Lamp ON > Page 9146
Disclaimer
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge
Technical Service Bulletin # 04S20S5 Date: 050201
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9155
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9156
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9157
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS was activated 9/9/2004.
FSA VIN LIST ACTIVATED? Yes.
Available by 9/24/04.
Owner names and addresses available by 10/1/04.
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
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9158
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs in coordination with the
available supply of parts.
^ 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.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
^ If a related damage condition exists that you believe to be caused by the covered condition,
repair as necessary and submit a claim in accordance with the Warranty and Policy Manual
(Section 4).
^ Refer to Attachment IV for additional information.
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 that might prevent the
repair of the covered condition, call the Special Service Support Center.
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 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 an owners'
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 out the VIN for this recall.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 04S20 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
A rental vehicle is only authorized when:
^ A vehicle arrives with a shattered back glass and a new glass must be ordered.
^ A vehicle arrives with a broken hinge and the vehicle cannot be driven while parts are on order.
^ The back glass breaks during or shortly after kit installation.
^ Shop volume or service scheduling makes it impossible to store vehicles which require bracket
replacement for any of the specified cure times. It is anticipated that rental vehicles will only be
required in limited circumstances.
CLAIMS PREPARATION AND SUBMISSION
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9159
^ 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.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
^ Refer to ACESII manual for claims preparation and submission information.
^ Anything other than the parts and labor operations specified in Attachment II must be on a related
damage claim.
Attachment II - Labor and Parts Information
[NEW!] LABOR ALLOWANCES
TOOL REQUIREMENTS
Rotunda Tool 501-040 is required to complete the ball stud bracket replacement. Each dealer will
be provided one applicator tool 501-040 at no charge. Tools have been mailed and should have
arrived at all dealerships by December 1, 2004. The tool shipping container will indicate "Enclosed
Adhesive Applicator Tool for Safety Recall 04S20.
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9160
PARTS REQUIREMENTS / ORDERING INFORMATION [NEW!] Parts ordering restrictions have
been lifted (an announcement was sent via DOES II on 1/27/05). Parts will not be direct shipped for
this recall. Order your parts requirements through normal order processing channels.
ORDER INFORMATION
The DOR/COR for this program is 50330. This number identifies parts ordered for this Safety
Recall through the Special Service Support center.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
UPDATED FEBRUARY 2005
CERTAIN 2002 AND 2003 MODEL YEAR EXPLORER/MOUNTAINEER VEHICLES - LIFTGATE
GLASS BALL STUD BRACKET AND HINGE REPLACEMENT
[NEW] Based on information received from Dealership technicians, we have made improvements
to this Attachment III. A Fordstar Broadcast has been developed in conjunction with the release of
this Dealer Bulletin and is available for viewing. Please take the time to view that broadcast.
OVERVIEW This program involves replacing the liftgate glass ball stud brackets and liftgate glass
hinges on certain 2002 and 2003 Model Year Explorer and Mountaineer vehicles.
^ On early built 2002 model year vehicles, the liftgate glass ball stud brackets and liftgate glass
hinges require replacement.
^ On later built 2002 and all early 2003 model year vehicles, only the liftgate glass hinges require
replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001) were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be easily identified as not having ANY
adhesive between them and the glass. When removing ball
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9161
stud bracket bolts, use extreme caution to turn the beauty bolt in the proper direction or the glass
may shatter under the pressure.
[NEW] SERVICE PRECAUTIONS
WARNING:
THE NEW HINGES AND PLASTIC HINGE GASKETS ARE IDENTIFIED AS EITHER
RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE OR DRIVER SIDE). IF INSTALLED ON THE
WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR
IDENTIFICATION DETAILS.
NOTE:
On some hinges the casting marks are very light and difficult to read. Look closely to make sure
each bracket is properly identified.
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER WILL RESULT IN
SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number - N621 926-S36)
nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they do not go on, use new 6-mm nuts.
INSPECTION
To properly identify the vehicle and decide which repairs to perform, inspect for the presence of
liftgate glass beauty bolts.
^ Early 2002 models use ball stud brackets that are secured with beauty bolts, which pass through
the glass (the head of the bolt is visible on the outside of the glass) and are bonded to the glass
about 150 mm (6 inches) from the top of the glass. See Figure 2. If beauty bolts are present, both
the liftgate ball stud brackets and hinges will be replaced. Perform BOTH the Liftgate Glass Hinge
Replacement and the Ball Stud Bracket Replacement. Begin your repairs with LIFTGATE GLASS
HINGE REPLACEMENT.
^ Later built 2002 and 2003 model year vehicles use revised ball stud brackets which are not
secured with beauty bolts. If beauty bolts are not present, only the hinges will be replaced. Perform
only the LIFTGATE GLASS HINGE REPLACEMENT.
LIFTGATE GLASS HINGE REPLACEMENT - ALL AFFECTED VEHICLES
NOTE:
The Hinge Replacement procedure must be completed prior to the Ball Stud Bracket procedure.
REMOVAL
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9162
WARNING:
BE SURE TO USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS SAFETY GLASSES AND
EQUIPMENT THAT WILL PROTECT AGAINST PERSONAL INJURY IN THE EVENT OF GLASS
BREAKAGE.
CAUTION:
Do not use power tools when working on the glass.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. Disconnect the liftgate glass support struts from both ends and remove from the vehicle.
3. Remove the jack stand and carefully close the glass making sure the striker is engaged in the
latch.
[NEW]4. CAUTION: The location of the original glass hinges must be clearly marked on the glass
to make sure the new hinges are accurately positioned and that the glass is properly aligned.
Failure to properly align the new hinges to these marks may result in glass shattering.
Using a grease pencil, a non-permanent marker or tape, outline the entire perimeter of the original
hinges to mark their exact location on the glass. See Figure 3.
5. Open the full liftgate.
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9163
6. Position the upper part of the liftgate trim panel away from the liftgate to gain access to the hinge
fasteners. See Figure 4.
7. Using a magnetic socket or tool, remove one (1) liftgate glass hinge-to-body nut, then the
hinge-to-glass bolt and remove one (1) hinge from the vehicle. Retain the plastic spacers from the
hinge-to-glass bolts for use with the new bolts. See Figure 5.
[NEW]8. Clean the glass, particularly at the edge around the hole, then inspect the edge of the hole
in the glass to see if it is chipped or cracked. If the glass is chipped or cracked, the glass must be
replaced. Discontinue this service in lieu of liftgate glass replacement.
INSTALLATION
[NEW] SERVICE PRECAUTIONS
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9164
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
CLEANED AND TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER
WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
WARNING:
THE NEW HINGES ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER
SIDE OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS
MAY SHATTER. SEE FIGURE 1 FOR IDENTIFICATION DETAILS.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
[NEW]CAUTION:
Be sure the glass and plastic hinge gaskets are very clean and contain no grit, dirt, sand or any
other foreign matter prior to installation. Even the smallest bit of any hard material captured
between the plastic gasket and the glass may cause the glass to shatter.
[NEW]NOTE:
When installing the plastic gasket onto the new hinge, be sure it sits flush onto the hinge surface.
Please note that some gaskets are known to fit very tightly around the threaded boss which may
make gasket installation difficult. Be sure the gasket is fully seated before installing the hinge.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number- N621926-S36) nuts
must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9165
do not go on, use new 6-mm nuts.
[NEW]1. WARNING: WHEN INSTALLING THE HINGE ASSEMBLY TO THE GLASS, BE SURE
THE SHOULDERS OF BOLTS, SPACERS AND GASKETS ARE PROPERLY ALIGNED INSIDE
THE HOLE IN THE GLASS. DO NOT ALLOW THEM TO SIT ON OR BE PROPPED UP ON THE
EDGE OF THE GLASS OR THE GLASS MAY SHATTER WHEN THE BOLTS ARE TIGHTENED
TO SPECIFICATION.
Transfer the plastic spacer from the old hinge-to-glass bolt onto the new bolt, then apply Thread
lock 262 (Motorcraft TA-26, red high strength) to the hinge-to-glass bolt threads even though it
already has lock tite, then position the hinge onto the vehicle.
[NEW]CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
2. Install the hinge bolt and nut FINGER TIGHT ONLY at this time.
3. Tighten the hinge BOLT FIRST to 8 Nm (71 lb-in).
4. Tighten the hinge NUT SECOND to 11 Nm (8 lb-ft or 97 lb-in).
5. Repeat Removal Steps 7 and 8 and Installation Steps 1 through 4 for the other hinge.
6. Reposition and secure the liftgate trim panel.
7. Close the liftgate.
NOTE:
If the beauty bolts are present (See INSPECTION), proceed to the Liftgate Ball Stud Bracket
Replacement procedure. If the beauty bolts are NOT present, complete Steps 8 and 9 and release
the vehicle.
8. Install the liftgate glass support struts.
9. Remove the jack stand and close the liftgate glass.
LIFTGATE GLASS BALL STUD BRACKET REPLACEMENT - EARLY 2002 MODEL YEAR
VEHICLES ONLY (VEHICLES WITH BEAUTY BOLTS)
CAUTION:
Do not use powertools when working on glass.
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9166
NOTE:
The new brackets are marked with a stamping, L or R followed by a number. They are NOT
interchangeable. The L is for the driver side of the glass and has left-hand threads. The R is for the
passenger side of the glass and has right-hand threads. The number can be ignored. See Figure 7.
CAUTION:
Due to the extremely short working time of the adhesive (less than one [1] minute), it is imperative
that only one (1) bracket be replaced at a time. Failure to specifically follow these instructions will
result in a ruined backglass or failure of the adhesive to bond properly to the glass.
NOTE:
Before the installation of the liftgate glass ball stud bracket, make sure that the interior surface of
the glass is clean and free of any visible moisture.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. WARNING: PERSONAL PROTECTIVE EQUIPMENT (SAFETY GLASSES) IS REQUIRED
WHEN WORKING WITH GLASS OR INJURY MAY OCCUR IN THE EVENT OF GLASS
BREAKAGE.
NOTE:
If you encounter ball stud brackets that do not twist off easily after removing the beauty bolt, it may
be due to an alternative adhesive that was applied as an interim repair. If the brackets cannot be
removed, the glass must be replaced. Discontinue this service in lieu of liftgate glass replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001), were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be identified as not having ANY
adhesive between them and the glass. When removing ball stud bracket bolts, use extreme caution
to turn the beauty bolt in the proper direction or the glass may shatter under the pressure.
Remove the bracket from the glass by first removing the beauty bolt using a T-30 Torx bit, then
twist the bracket off the glass using a 17-mm box-end wrench.
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9167
NOTE:
With the liftgate glass open, be sure to properly orient the new brackets with the ball stud pointing
upward and outward. See Figure 8.
3. Hold the new bracket in position on the glass with the ball stud pointing UP and OUT (with the
liftgate glass open). Mark the area around the bracket using masking tape or vinyl tape. Leave a
space approximately 7 mm (1/4 in) between the edge of the bracket and the tape. The taped-off
area should be approximately 57-mm (2-1/4 in) wide and 89-mm (3-1/2 in) high. See Figure 9 for
proper placement and dimensions. After the tape is applied, remove the bracket. The tape will be
used as an alignment guide, therefore, keep the tape in place until completing the final bracket
alignment.
4. CAUTION: Care should be taken to avoid damage to the frosted coating on the glass.
Completely remove all existing adhesive from the glass using a sharp razor blade scraper. Clean
the area of any residual adhesive using the supplied Scotch Brite(R) scuff pad. See Figure 10.
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9168
[NEW] 5. Clean the area using the supplied alcohol wipe and allow it to dry completely, ensuring no
moisture is present. Then, inspect the edge of the hole for any chips or cracks. If the glass is
chipped or cracked, the glass must be replaced. Discontinue this service in lieu of liftgate glass
replacement.
CAUTION:
This primer requires a minimum of fifteen (15) minutes dry time before adhesive can be applied.
Failure to wait the necessary fifteen (15) minutes will lead to the failure of the adhesive.
6. Using one of the supplied dauber brushes, neatly apply a thin coat of Chemlok 144(R) primer to
the taped-off area, then carefully remove the tape. Allow the primer to dry for at least fifteen (15)
minutes, ensuring no moisture is present before installing the new brackets.
While waiting for the primer to dry, remove the original bracket and prepare the surface 1 on the
opposite side of the glass (repeat Steps 2 through 7).
7. NOTE: When scuffing the new bracket, use light pressure to avoid exposing bare metal.
Using the Scotch Brite(R) scuff pad, carefully scuff the backside of both new brackets so that the
surface no longer has a shiny appearance, then wipe it clean with one of the supplied alcohol
wipes.
[NEW]8. CAUTION: Be sure the glass and plastic washers are very clean and contain no grit, dirt,
sand or any other foreign matter prior to installation. Even the smallest bit of any hard material
captured between the plastic washer and the glass may cause the glass to shatter.
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9169
Install the plastic spacer (with locating tab) and rubber washer onto the new brackets as shown in
Figure 11. Also, place a plastic washer onto the beauty bolt with the collar toward the glass.
9. CAUTION: Failure to prepare the adhesive cartridge and mixer tip as described may cause
insufficient mixing of the product. This may lead to insufficient bonding of the bracket(s) to the
glass.
Assemble the adhesive cartridge and application tool and purge the cartridge as follows:
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9170
A) Trim approximately 13 mm (0.5 in) off the top of both mixer tips, down to the last ring. See
Figure 12.
B) Install the Fusor(R) # 143 adhesive cartridge into the application tool (No. 501-040).
C) Dispense a small amount of adhesive from the cartridge onto a piece of scrap cardboard to level
the plungers and to ensure an even flow of both components.
D) Install one (1) mixer tip onto the cartridge and dispense a 75-mm (3-in) bead of the adhesive
onto a piece of scrap cardboard (until the product is evenly mixed and the color is consistent).
NOTE:
Due to the working times involved and the necessity of changing mixing tips on the application tool,
these instructions are written to perform installation of the left-side bracket first, then the right-side
bracket. Please review these instructions and understand the process before proceeding with
adhesive application and bracket installation.
10. CAUTION: The adhesive used to install the liftgate glass ball stud brackets will require at least
two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder
environment before two hours has elapsed, cure time will increase substantially before the liftgate
glass struts can be reattached. The following guidelines must be followed in order to ensure
properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
NOTE:
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9171
Once the adhesive mixes. you will have less than one (1) minute to install the new bracket before
the adhesive begins to set. The adhesive will require at least two (2) hours at 70°F or higher to cure
before the liftgate glass support struts can be attached.
NOTE:
Keep the used mixer tip attached to the cartridge after use.
After the primer has dried for fifteen (15) minutes, apply three (3) large beads (9-10 mm in
diameter) of adhesive to the backside of the new left-side bracket. See Figure 13.
11. NOTE: Left side bolts and brackets have left-hand threads.
NOTE:
Once the bracket is in position, DO NOT lift it from the glass. You may twist or turn the bracket
slightly, but it must remain in contact with the glass to prevent the formation of air bubbles in the
adhesive.
With the correct left-hand thread beauty bolt and plastic washer ready in one hand, position the
new left-side bracket onto the glass and align it with the beauty bolt hole and parallel with the edge
of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9172
While holding the bracket nut with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
12. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
13. NOTE: Be sure to use a new mixer tip for each bracket.
Install a new trimmed mixer tip onto the adhesive cartridge, then dispense a 75-mm (3-in) bead of
adhesive onto a piece of scrap cardboard to ensure the product is evenly mixed in the tip and is
ready for application.
14. Apply three (3) large beads (9-10 mm in diameter) of adhesive to the backside of the new
right-side bracket. See Figure 13.
15. With the correct right-hand thread beauty bolt and plastic washer ready in one hand position
the new right-side bracket onto the glass and align it with the beauty bolt hole and parallel with the
edge of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
While holding the bracket with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
16. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9173
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
17. Remove the jack stand, carefully close the glass making sure the striker is engaged in the
latch, and allow the adhesive to cure as indicated in the caution above.
18. After the adhesive has cured as required per the caution above, reattach the liftgate glass
support struts before releasing the vehicle to the customer.
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9174
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9175
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9176
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9177
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9178
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9179
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9180
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 04S20S5 > Feb > 05
> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9181
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9182
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9183
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> Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9184
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Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > NHTSA04V442000 >
Sep > 04 > Recall 04V244000: Liftgate Glass Strut/Hinge Defect
Trunk / Liftgate Shock / Support: Recalls Recall 04V244000: Liftgate Glass Strut/Hinge Defect
Make / Models : Model/Build Years: Ford / Explorer 2002-2003 Ford / Mountaineer 2002-2003
MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V442000 Recall
Date : SEP 09, 2004
COMPONENT: Structure: Body: Hatchback/Liftgate: Hinge and Attachments
Potential Number Of Units Affected : 955732
SUMMARY: On certain sport utility vehicles, the liftgate glass strut may become disengaged or the
hinge may fracture allowing the glass to fall and possibly break.
CONSEQUENCE: If the hinge should fracture, there is a potential for the glass to fall and ultimately
break and personal injuries could occur.
REMEDY: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the
vehicles built from August 1, 2000 through March 3, 2002, The dealers will replace the hinges and
liftgate strut bracket. On vehicles built from March 3, 2002 through June 23, 2003, The Dealers will
only replace the hinges. The recall began on September 30, 2004. Owners should contact Ford at
1-800-392-3673.
NOTES: Ford Recall NO. 04S20. Customers can also contact The National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
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> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge
Technical Service Bulletin # 04S20S5 Date: 050201
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> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9194
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9195
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> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9196
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS was activated 9/9/2004.
FSA VIN LIST ACTIVATED? Yes.
Available by 9/24/04.
Owner names and addresses available by 10/1/04.
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
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Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs in coordination with the
available supply of parts.
^ 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.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
^ If a related damage condition exists that you believe to be caused by the covered condition,
repair as necessary and submit a claim in accordance with the Warranty and Policy Manual
(Section 4).
^ Refer to Attachment IV for additional information.
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 that might prevent the
repair of the covered condition, call the Special Service Support Center.
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 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 an owners'
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 out the VIN for this recall.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 04S20 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
A rental vehicle is only authorized when:
^ A vehicle arrives with a shattered back glass and a new glass must be ordered.
^ A vehicle arrives with a broken hinge and the vehicle cannot be driven while parts are on order.
^ The back glass breaks during or shortly after kit installation.
^ Shop volume or service scheduling makes it impossible to store vehicles which require bracket
replacement for any of the specified cure times. It is anticipated that rental vehicles will only be
required in limited circumstances.
CLAIMS PREPARATION AND SUBMISSION
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^ 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.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
^ Refer to ACESII manual for claims preparation and submission information.
^ Anything other than the parts and labor operations specified in Attachment II must be on a related
damage claim.
Attachment II - Labor and Parts Information
[NEW!] LABOR ALLOWANCES
TOOL REQUIREMENTS
Rotunda Tool 501-040 is required to complete the ball stud bracket replacement. Each dealer will
be provided one applicator tool 501-040 at no charge. Tools have been mailed and should have
arrived at all dealerships by December 1, 2004. The tool shipping container will indicate "Enclosed
Adhesive Applicator Tool for Safety Recall 04S20.
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PARTS REQUIREMENTS / ORDERING INFORMATION [NEW!] Parts ordering restrictions have
been lifted (an announcement was sent via DOES II on 1/27/05). Parts will not be direct shipped for
this recall. Order your parts requirements through normal order processing channels.
ORDER INFORMATION
The DOR/COR for this program is 50330. This number identifies parts ordered for this Safety
Recall through the Special Service Support center.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
UPDATED FEBRUARY 2005
CERTAIN 2002 AND 2003 MODEL YEAR EXPLORER/MOUNTAINEER VEHICLES - LIFTGATE
GLASS BALL STUD BRACKET AND HINGE REPLACEMENT
[NEW] Based on information received from Dealership technicians, we have made improvements
to this Attachment III. A Fordstar Broadcast has been developed in conjunction with the release of
this Dealer Bulletin and is available for viewing. Please take the time to view that broadcast.
OVERVIEW This program involves replacing the liftgate glass ball stud brackets and liftgate glass
hinges on certain 2002 and 2003 Model Year Explorer and Mountaineer vehicles.
^ On early built 2002 model year vehicles, the liftgate glass ball stud brackets and liftgate glass
hinges require replacement.
^ On later built 2002 and all early 2003 model year vehicles, only the liftgate glass hinges require
replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001) were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be easily identified as not having ANY
adhesive between them and the glass. When removing ball
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stud bracket bolts, use extreme caution to turn the beauty bolt in the proper direction or the glass
may shatter under the pressure.
[NEW] SERVICE PRECAUTIONS
WARNING:
THE NEW HINGES AND PLASTIC HINGE GASKETS ARE IDENTIFIED AS EITHER
RIGHT-HAND OR LEFT-HAND (PASSENGER SIDE OR DRIVER SIDE). IF INSTALLED ON THE
WRONG SIDE OF THE VEHICLE, THE GLASS MAY SHATTER. SEE FIGURE 1 FOR
IDENTIFICATION DETAILS.
NOTE:
On some hinges the casting marks are very light and difficult to read. Look closely to make sure
each bracket is properly identified.
WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER WILL RESULT IN
SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number - N621 926-S36)
nuts must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they do not go on, use new 6-mm nuts.
INSPECTION
To properly identify the vehicle and decide which repairs to perform, inspect for the presence of
liftgate glass beauty bolts.
^ Early 2002 models use ball stud brackets that are secured with beauty bolts, which pass through
the glass (the head of the bolt is visible on the outside of the glass) and are bonded to the glass
about 150 mm (6 inches) from the top of the glass. See Figure 2. If beauty bolts are present, both
the liftgate ball stud brackets and hinges will be replaced. Perform BOTH the Liftgate Glass Hinge
Replacement and the Ball Stud Bracket Replacement. Begin your repairs with LIFTGATE GLASS
HINGE REPLACEMENT.
^ Later built 2002 and 2003 model year vehicles use revised ball stud brackets which are not
secured with beauty bolts. If beauty bolts are not present, only the hinges will be replaced. Perform
only the LIFTGATE GLASS HINGE REPLACEMENT.
LIFTGATE GLASS HINGE REPLACEMENT - ALL AFFECTED VEHICLES
NOTE:
The Hinge Replacement procedure must be completed prior to the Ball Stud Bracket procedure.
REMOVAL
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WARNING:
BE SURE TO USE PERSONAL PROTECTIVE EQUIPMENT SUCH AS SAFETY GLASSES AND
EQUIPMENT THAT WILL PROTECT AGAINST PERSONAL INJURY IN THE EVENT OF GLASS
BREAKAGE.
CAUTION:
Do not use power tools when working on the glass.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. Disconnect the liftgate glass support struts from both ends and remove from the vehicle.
3. Remove the jack stand and carefully close the glass making sure the striker is engaged in the
latch.
[NEW]4. CAUTION: The location of the original glass hinges must be clearly marked on the glass
to make sure the new hinges are accurately positioned and that the glass is properly aligned.
Failure to properly align the new hinges to these marks may result in glass shattering.
Using a grease pencil, a non-permanent marker or tape, outline the entire perimeter of the original
hinges to mark their exact location on the glass. See Figure 3.
5. Open the full liftgate.
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6. Position the upper part of the liftgate trim panel away from the liftgate to gain access to the hinge
fasteners. See Figure 4.
7. Using a magnetic socket or tool, remove one (1) liftgate glass hinge-to-body nut, then the
hinge-to-glass bolt and remove one (1) hinge from the vehicle. Retain the plastic spacers from the
hinge-to-glass bolts for use with the new bolts. See Figure 5.
[NEW]8. Clean the glass, particularly at the edge around the hole, then inspect the edge of the hole
in the glass to see if it is chipped or cracked. If the glass is chipped or cracked, the glass must be
replaced. Discontinue this service in lieu of liftgate glass replacement.
INSTALLATION
[NEW] SERVICE PRECAUTIONS
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WARNING:
THE PLASTIC SPACER LOCATED UNDER THE ORIGINAL HINGE-TO-GLASS BOLT MUST BE
CLEANED AND TRANSFERRED TO THE NEW BOLT. FAILURE TO INSTALL THIS SPACER
WILL RESULT IN SHATTERING THE GLASS UPON BOLT INSTALLATION. SEE FIGURE 6.
WARNING:
THE NEW HINGES ARE IDENTIFIED AS EITHER RIGHT-HAND OR LEFT-HAND (PASSENGER
SIDE OR DRIVER SIDE). IF INSTALLED ON THE WRONG SIDE OF THE VEHICLE, THE GLASS
MAY SHATTER. SEE FIGURE 1 FOR IDENTIFICATION DETAILS.
CAUTION:
DO NOT transfer the steel washer under the plastic hinge gasket from the old hinge to the new
hinge. The plastic gasket on the new hinge will not fit properly causing improper hinge installation.
[NEW]CAUTION:
Be sure the glass and plastic hinge gaskets are very clean and contain no grit, dirt, sand or any
other foreign matter prior to installation. Even the smallest bit of any hard material captured
between the plastic gasket and the glass may cause the glass to shatter.
[NEW]NOTE:
When installing the plastic gasket onto the new hinge, be sure it sits flush onto the hinge surface.
Please note that some gaskets are known to fit very tightly around the threaded boss which may
make gasket installation difficult. Be sure the gasket is fully seated before installing the hinge.
NOTE:
2002 model year vehicles built before April 30, 2001 may have been produced with 5-mm
hinge-to-body nuts. When installing the new hinges, new 6-mm (Part Number- N621926-S36) nuts
must be used. If 6-mm nuts are removed from the original hinge, retain for re-use.
To determine if new 6-mm nuts are required, attempt to install the original nuts on the new hinge by
hand. If they go on easily, re-use the nuts. If they
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do not go on, use new 6-mm nuts.
[NEW]1. WARNING: WHEN INSTALLING THE HINGE ASSEMBLY TO THE GLASS, BE SURE
THE SHOULDERS OF BOLTS, SPACERS AND GASKETS ARE PROPERLY ALIGNED INSIDE
THE HOLE IN THE GLASS. DO NOT ALLOW THEM TO SIT ON OR BE PROPPED UP ON THE
EDGE OF THE GLASS OR THE GLASS MAY SHATTER WHEN THE BOLTS ARE TIGHTENED
TO SPECIFICATION.
Transfer the plastic spacer from the old hinge-to-glass bolt onto the new bolt, then apply Thread
lock 262 (Motorcraft TA-26, red high strength) to the hinge-to-glass bolt threads even though it
already has lock tite, then position the hinge onto the vehicle.
[NEW]CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
2. Install the hinge bolt and nut FINGER TIGHT ONLY at this time.
3. Tighten the hinge BOLT FIRST to 8 Nm (71 lb-in).
4. Tighten the hinge NUT SECOND to 11 Nm (8 lb-ft or 97 lb-in).
5. Repeat Removal Steps 7 and 8 and Installation Steps 1 through 4 for the other hinge.
6. Reposition and secure the liftgate trim panel.
7. Close the liftgate.
NOTE:
If the beauty bolts are present (See INSPECTION), proceed to the Liftgate Ball Stud Bracket
Replacement procedure. If the beauty bolts are NOT present, complete Steps 8 and 9 and release
the vehicle.
8. Install the liftgate glass support struts.
9. Remove the jack stand and close the liftgate glass.
LIFTGATE GLASS BALL STUD BRACKET REPLACEMENT - EARLY 2002 MODEL YEAR
VEHICLES ONLY (VEHICLES WITH BEAUTY BOLTS)
CAUTION:
Do not use powertools when working on glass.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9205
NOTE:
The new brackets are marked with a stamping, L or R followed by a number. They are NOT
interchangeable. The L is for the driver side of the glass and has left-hand threads. The R is for the
passenger side of the glass and has right-hand threads. The number can be ignored. See Figure 7.
CAUTION:
Due to the extremely short working time of the adhesive (less than one [1] minute), it is imperative
that only one (1) bracket be replaced at a time. Failure to specifically follow these instructions will
result in a ruined backglass or failure of the adhesive to bond properly to the glass.
NOTE:
Before the installation of the liftgate glass ball stud bracket, make sure that the interior surface of
the glass is clean and free of any visible moisture.
1. Open the liftgate glass and support the glass with a jack stand positioned under the striker.
2. WARNING: PERSONAL PROTECTIVE EQUIPMENT (SAFETY GLASSES) IS REQUIRED
WHEN WORKING WITH GLASS OR INJURY MAY OCCUR IN THE EVENT OF GLASS
BREAKAGE.
NOTE:
If you encounter ball stud brackets that do not twist off easily after removing the beauty bolt, it may
be due to an alternative adhesive that was applied as an interim repair. If the brackets cannot be
removed, the glass must be replaced. Discontinue this service in lieu of liftgate glass replacement.
CAUTION:
Several early built 2002 model year vehicles (produced from November 2000 through
approximately February 2001), were produced with right-hand threads on both right- and left-side
ball stud brackets. After this time, the left-side bracket had left-hand threads and the right-side
bracket had right-hand threads. The early brackets may also be identified as not having ANY
adhesive between them and the glass. When removing ball stud bracket bolts, use extreme caution
to turn the beauty bolt in the proper direction or the glass may shatter under the pressure.
Remove the bracket from the glass by first removing the beauty bolt using a T-30 Torx bit, then
twist the bracket off the glass using a 17-mm box-end wrench.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9206
NOTE:
With the liftgate glass open, be sure to properly orient the new brackets with the ball stud pointing
upward and outward. See Figure 8.
3. Hold the new bracket in position on the glass with the ball stud pointing UP and OUT (with the
liftgate glass open). Mark the area around the bracket using masking tape or vinyl tape. Leave a
space approximately 7 mm (1/4 in) between the edge of the bracket and the tape. The taped-off
area should be approximately 57-mm (2-1/4 in) wide and 89-mm (3-1/2 in) high. See Figure 9 for
proper placement and dimensions. After the tape is applied, remove the bracket. The tape will be
used as an alignment guide, therefore, keep the tape in place until completing the final bracket
alignment.
4. CAUTION: Care should be taken to avoid damage to the frosted coating on the glass.
Completely remove all existing adhesive from the glass using a sharp razor blade scraper. Clean
the area of any residual adhesive using the supplied Scotch Brite(R) scuff pad. See Figure 10.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9207
[NEW] 5. Clean the area using the supplied alcohol wipe and allow it to dry completely, ensuring no
moisture is present. Then, inspect the edge of the hole for any chips or cracks. If the glass is
chipped or cracked, the glass must be replaced. Discontinue this service in lieu of liftgate glass
replacement.
CAUTION:
This primer requires a minimum of fifteen (15) minutes dry time before adhesive can be applied.
Failure to wait the necessary fifteen (15) minutes will lead to the failure of the adhesive.
6. Using one of the supplied dauber brushes, neatly apply a thin coat of Chemlok 144(R) primer to
the taped-off area, then carefully remove the tape. Allow the primer to dry for at least fifteen (15)
minutes, ensuring no moisture is present before installing the new brackets.
While waiting for the primer to dry, remove the original bracket and prepare the surface 1 on the
opposite side of the glass (repeat Steps 2 through 7).
7. NOTE: When scuffing the new bracket, use light pressure to avoid exposing bare metal.
Using the Scotch Brite(R) scuff pad, carefully scuff the backside of both new brackets so that the
surface no longer has a shiny appearance, then wipe it clean with one of the supplied alcohol
wipes.
[NEW]8. CAUTION: Be sure the glass and plastic washers are very clean and contain no grit, dirt,
sand or any other foreign matter prior to installation. Even the smallest bit of any hard material
captured between the plastic washer and the glass may cause the glass to shatter.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9208
Install the plastic spacer (with locating tab) and rubber washer onto the new brackets as shown in
Figure 11. Also, place a plastic washer onto the beauty bolt with the collar toward the glass.
9. CAUTION: Failure to prepare the adhesive cartridge and mixer tip as described may cause
insufficient mixing of the product. This may lead to insufficient bonding of the bracket(s) to the
glass.
Assemble the adhesive cartridge and application tool and purge the cartridge as follows:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9209
A) Trim approximately 13 mm (0.5 in) off the top of both mixer tips, down to the last ring. See
Figure 12.
B) Install the Fusor(R) # 143 adhesive cartridge into the application tool (No. 501-040).
C) Dispense a small amount of adhesive from the cartridge onto a piece of scrap cardboard to level
the plungers and to ensure an even flow of both components.
D) Install one (1) mixer tip onto the cartridge and dispense a 75-mm (3-in) bead of the adhesive
onto a piece of scrap cardboard (until the product is evenly mixed and the color is consistent).
NOTE:
Due to the working times involved and the necessity of changing mixing tips on the application tool,
these instructions are written to perform installation of the left-side bracket first, then the right-side
bracket. Please review these instructions and understand the process before proceeding with
adhesive application and bracket installation.
10. CAUTION: The adhesive used to install the liftgate glass ball stud brackets will require at least
two (2) hours to cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder
environment before two hours has elapsed, cure time will increase substantially before the liftgate
glass struts can be reattached. The following guidelines must be followed in order to ensure
properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
NOTE:
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9210
Once the adhesive mixes. you will have less than one (1) minute to install the new bracket before
the adhesive begins to set. The adhesive will require at least two (2) hours at 70°F or higher to cure
before the liftgate glass support struts can be attached.
NOTE:
Keep the used mixer tip attached to the cartridge after use.
After the primer has dried for fifteen (15) minutes, apply three (3) large beads (9-10 mm in
diameter) of adhesive to the backside of the new left-side bracket. See Figure 13.
11. NOTE: Left side bolts and brackets have left-hand threads.
NOTE:
Once the bracket is in position, DO NOT lift it from the glass. You may twist or turn the bracket
slightly, but it must remain in contact with the glass to prevent the formation of air bubbles in the
adhesive.
With the correct left-hand thread beauty bolt and plastic washer ready in one hand, position the
new left-side bracket onto the glass and align it with the beauty bolt hole and parallel with the edge
of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
CAUTION:
When working with glass, the torque specifications are very critical. Be sure the torque wrench
used during this service has recently been calibrated so the fasteners are not over-tightened or
under-tightened. Failure to use a calibrated torque wrench may result in glass shattering either
during the repair or possibly after the repair is completed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9211
While holding the bracket nut with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
12. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
13. NOTE: Be sure to use a new mixer tip for each bracket.
Install a new trimmed mixer tip onto the adhesive cartridge, then dispense a 75-mm (3-in) bead of
adhesive onto a piece of scrap cardboard to ensure the product is evenly mixed in the tip and is
ready for application.
14. Apply three (3) large beads (9-10 mm in diameter) of adhesive to the backside of the new
right-side bracket. See Figure 13.
15. With the correct right-hand thread beauty bolt and plastic washer ready in one hand position
the new right-side bracket onto the glass and align it with the beauty bolt hole and parallel with the
edge of the glass. Install the beauty bolt and snug it down hand tight.
CAUTION:
While tightening the bolt, some adhesive will be squeezed out from under the bracket.
DO NOT WIPE AWAY THE EXCESS ADHESIVE.
While holding the bracket with a 17-mm box or open-end wrench, tighten the bolt to 25 Nm (18
lb-ft). See Figure 14.
16. Once the new bracket is in place, make sure the edge of the bracket is parallel to the edge of
the glass. If the bracket position needs to be adjusted, you may turn it using a 17-mm wrench. DO
NOT separate the bracket from the glass once the bracket is in position.
CAUTION:
The adhesive used to install the liftgate glass ball stud brackets will require at least two (2) hours to
cure at 21° C (70° F) or higher. If the vehicle must be moved to a much colder environment before
two hours has elapsed, cure time will increase substantially before the liftgate glass struts can be
reattached. The following guidelines must be followed in order to ensure properly cured adhesive:
^ Two (2) hour cure time at 21° C (70° F) (Preferred)
^ Three (3) hour cure time at 10° C (50° F)
^ Seven (7) hour cure time at 0° C (32° F)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9212
^ Below 0°C (32° F), call the Special Service Support Center to review the particular circumstances
and obtain further direction.
17. Remove the jack stand, carefully close the glass making sure the striker is engaged in the
latch, and allow the adhesive to cure as indicated in the caution above.
18. After the adhesive has cured as required per the caution above, reattach the liftgate glass
support struts before releasing the vehicle to the customer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9213
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9214
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9215
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9216
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9217
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9218
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9219
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9220
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9221
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9222
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> 04S20S5 > Feb > 05 > Recall - Replace Liftgate Glass Ball Stud Bracket/Hinge > Page 9223
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support:
> NHTSA04V442000 > Sep > 04 > Recall 04V244000: Liftgate Glass Strut/Hinge Defect
Trunk / Liftgate Shock / Support: All Technical Service Bulletins Recall 04V244000: Liftgate Glass
Strut/Hinge Defect
Make / Models : Model/Build Years: Ford / Explorer 2002-2003 Ford / Mountaineer 2002-2003
MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V442000 Recall
Date : SEP 09, 2004
COMPONENT: Structure: Body: Hatchback/Liftgate: Hinge and Attachments
Potential Number Of Units Affected : 955732
SUMMARY: On certain sport utility vehicles, the liftgate glass strut may become disengaged or the
hinge may fracture allowing the glass to fall and possibly break.
CONSEQUENCE: If the hinge should fracture, there is a potential for the glass to fall and ultimately
break and personal injuries could occur.
REMEDY: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the
vehicles built from August 1, 2000 through March 3, 2002, The dealers will replace the hinges and
liftgate strut bracket. On vehicles built from March 3, 2002 through June 23, 2003, The Dealers will
only replace the hinges. The recall began on September 30, 2004. Owners should contact Ford at
1-800-392-3673.
NOTES: Ford Recall NO. 04S20. Customers can also contact The National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information >
Technical Service Bulletins > Customer Interest for License Plate Bracket: > 05-9-5 > May > 05 > Body - License Plate
Shield Cracked/Broken
License Plate Bracket: Customer Interest Body - License Plate Shield Cracked/Broken
TSB 05-9-5
05/16/05
LICENSE PLATE SHIELD CRACKS OR BREAKS - VEHICLES BUILT BEFORE 10/14/2004 WITH
XLS TRIM
FORD: 2003-2005 Explorer
ISSUE Some 2003-2005 Explorer 4dr vehicles built before 10/14/2004 and with XLS trim, may
exhibit the license plate shield cracking or breaking in cold temperatures. This may be due to the
liftgate release handle coming in contact with the shield during use.
ACTION
If the license plate shield is damaged, replace the shield and the rear liftgate release handle.
SERVICE PROCEDURE
1. Replace the liftgate release handle per Section 501-14 of the Workshop Manual.
LICENSE PLATE SHIELD REPLACEMENT
1. Remove the four (4) attachment bolts and remove the license plate shield (Figure 1).
2. Install the replacement shield and torque the bolts to 108 lb-in (12 N.m).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050905A 2003-2005 Explorer 4 Door 0.4 Hr.
Replace The Rear Liftgate Release Handle And License Plate Shield (Do Not Use With 46404B,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information >
Technical Service Bulletins > Customer Interest for License Plate Bracket: > 05-9-5 > May > 05 > Body - License Plate
Shield Cracked/Broken > Page 9237
46404B10, P42D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7843400 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for License Plate Bracket: > 05-9-5 > May > 05 > Body License Plate Shield Cracked/Broken
License Plate Bracket: All Technical Service Bulletins Body - License Plate Shield Cracked/Broken
TSB 05-9-5
05/16/05
LICENSE PLATE SHIELD CRACKS OR BREAKS - VEHICLES BUILT BEFORE 10/14/2004 WITH
XLS TRIM
FORD: 2003-2005 Explorer
ISSUE Some 2003-2005 Explorer 4dr vehicles built before 10/14/2004 and with XLS trim, may
exhibit the license plate shield cracking or breaking in cold temperatures. This may be due to the
liftgate release handle coming in contact with the shield during use.
ACTION
If the license plate shield is damaged, replace the shield and the rear liftgate release handle.
SERVICE PROCEDURE
1. Replace the liftgate release handle per Section 501-14 of the Workshop Manual.
LICENSE PLATE SHIELD REPLACEMENT
1. Remove the four (4) attachment bolts and remove the license plate shield (Figure 1).
2. Install the replacement shield and torque the bolts to 108 lb-in (12 N.m).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050905A 2003-2005 Explorer 4 Door 0.4 Hr.
Replace The Rear Liftgate Release Handle And License Plate Shield (Do Not Use With 46404B,
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for License Plate Bracket: > 05-9-5 > May > 05 > Body License Plate Shield Cracked/Broken > Page 9243
46404B10, P42D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7843400 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation
Body / Frame Mount Bushing: Description and Operation
FRAME AND BODY MOUNTING
Explorer Sport/Sport Trac
Explorer Sport/Sport Trac
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9248
Explorer Sport/Sport Trac
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9249
Explorer Sport/Sport Trac
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9250
Explorer Sport
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9251
Explorer Sport
The frame consists of two steel channel rails, a rear crossmember, additional support
crossmembers and a front crossmember.
The rails and crossmembers arc not to be removed from the frame (5005) for repair except for the
spare tire carrier plate. A front frame rail repair kit (5D058 and 5D059) is available if the front rail is
to be repaired.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Material
Material
Removal and Installation
Upper and Lower Insulator
NOTE: Left side shown, right side similar.
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.
CAUTION: Do not correct a serious misalignment with one jacking operation. Align each section
proportionately until the correct dimensions are obtained.
NOTE: To make sure of accurate measurements, remove all trim from the reference points to
expose bare metal.
3. Position back the carpeting and remove the body insulator plug.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9254
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.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9255
Body / Frame Mount Bushing: Service and Repair Body Support - Number 2
BODY SUPPORT - NUMBER 2
Material
Material
Removal and Installation
Upper and Lower Insulator
NOTE: Left side shown, right side similar.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9256
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9257
Body / Frame Mount Bushing: Service and Repair Body Support - Number 3
BODY SUPPORT - NUMBER 3
Material
Material
Removal and Installation
Upper and Lower Insulator - All Vehicles
NOTE: Left side shown, right side similar.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9258
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9259
Body / Frame Mount Bushing: Service and Repair Body Support - Number 4
BODY SUPPORT - NUMBER 4
Material
Material
Removal and Installation
Upper and Lower Insulator
NOTE: Left side shown, right side similar.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9260
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.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 9261
Body / Frame Mount Bushing: Service and Repair Body Support - Radiator Support
BODY SUPPORT - RADIATOR SUPPORT
Removal and Installation
Upper and Lower Insulator
NOTE: Left side shown, right side similar.
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Material
Material
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console
Console: Service and Repair Floor Console
FLOOR CONSOLE
REMOVAL
1. Remove components in the order indicated in the illustration and table.
Item 9: Floor Console Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console > Page 9271
1. Release the two floor console front clips.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console > Page 9272
Console: Service and Repair Overhead Console
OVERHEAD CONSOLE
NOTE: Overhead console with garage door opener storage compartment shown. All other consoles
similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service Precautions > Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service Precautions > Technician Safety Information > Page 9278
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9281
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9282
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9283
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9284
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9285
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9286
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9287
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9288
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9289
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9290
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9291
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9292
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9293
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9294
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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9295
10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9296
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9297
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9298
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9299
- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9300
10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9301
12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9302
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9303
Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9304
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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9305
3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9306
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9307
11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9308
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9309
All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9310
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9311
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9312
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9313
13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9314
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9315
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9316
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9317
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Page 9318
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Technician Safety Information
Headliner: Technician Safety Information
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation
procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Technician Safety Information > Page 9323
Headliner: Vehicle Damage Warnings
CAUTION:
- To prevent bending or damaging the headliner, an assistant is required to support the liner while
carrying out the remaining steps.
- To prevent damaging the garment hanger retainer, use a 3/16-inch fiat blade screwdriver to carry
out this step.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Page 9324
Headliner: Service and Repair
HEADLINER
NOTE: Headliner with roof opening panel is shown. Headliner without opening panel is similar.
REMOVAL
1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
If equipped, deactivate the supplemental restraint system (SRS).
2. If equipped, remove the rear auxiliary A/C controls. 3. If equipped, remove the rear
entertainment system. 4. Remove the overhead console. 5. Remove the A-, B-, C- and D-pillar trim
panels. 6. If equipped, remove the gimp around the roof opening panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Page 9325
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Page 9326
Part 2
7. Remove the components in the order listed in the illustration and table.
Item 1: Sun Visor Retainer Cover Removal Note
1. Release the sun visor retainer cover tab.
2. Slide a small flat-blade screwdriver under the cover to release the second retainer tab.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Page 9327
3. Rotate the cover to remove.
Item 4: Sun Visor Electrical Connector Removal Note
1. Carefully lower the headliner at the corner of the sun visor location to access the electrical
connector.
Item 6: Interior Mirror Electrical Connector Removal Note
1. If equipped, disconnect the electronic compass sensor electrical connector.
2. If equipped, disconnect the interior mirror electrical connector.
Item 7 and Item 9: Cargo Lamp Cover Removal Note
1. Use a thin-bladed tool to carefully remove the lamp cover.
Item 11: Headliner Electrical Connectors (Rear) Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Page 9328
1. Remove the upper air duct.
- Remove the pin-type retainers.
- Push down on the duct, tilt top outward and pull upward to remove.
2. Remove the lower air duct.
3. Disconnect the electrical connector located at the C-pillar.
- Release the wiring harness pin-type retainers.
4. Disconnect all of the electrical connectors.
Item 13: Headliner Electrical Connector (Front) Removal Note
1. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service
Precautions > Page 9329
Item 15: Sun Visor Center Retainer Removal Note
CAUTION: To prevent bending or damaging the headliner, an assistant is required to support the
liner while carrying out the remaining steps.
1. Open the center retainer cover to access the screw.
Item 16: Garment Hook Removal Note
1. CAUTION: To prevent damaging the garment hanger retainer, use a 3/16-inch fiat blade
screwdriver to carry out this step.
Remove the second and third row garment hooks. Open the access cover and insert a 3/16-inch flat blade screwdriver into the garment hanger slot
and turn 90 degrees so that it engages the plastic component slot. This spreads the steel
attachment clip wings to allow the plastic component to disengage. The clip remains engaged in
the sheet metal.
INSTALLATION
1. Install in the reverse order of removal.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
If equipped, reactivate the supplemental restraint system (SRS).
Item 4: Sun Visor Electrical Connector Installation Note
1. Install new tape around the sun visor wiring harness-to-headliner before installing the visor.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim Panel
Trim Panel: Service and Repair Interior Trim Panel
INTERIOR TRIM PANELS
Torx Bit, Safety Belt Bolt
SPECIAL TOOL(S)
NOTE: RH side is shown. LH side is similar.
REMOVAL
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim Panel > Page 9334
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim Panel > Page 9335
Part 2
1. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 6: Cowl Side Trim Panel Removal Note
1. To remove the LH cowl side trim panel, remove the hood release lever.
1 Remove the screw.
2 Remove the hood release lever.
2. Remove the lower cowl trim panel.
1 Remove the pin-type retainer.
2 Remove the lower cowl trim panel.
Item 13: D-Pillar Lower Safety Belt Anchor Bolt Removal Note
1. If equipped with third-row seating, release the two levers located at each lower outboard edge of
the third row seat cushion to access the D-pillar
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim Panel > Page 9336
lower safety belt anchor bolt.
Item 14: D-Pillar Trim Panel Removal Note
1. Remove the upper headliner trim panel.
Item 16: Rear Quarter Trim Panel Removal Note
1. If equipped with third-row seating, remove the third-row seat.
INSTALLATION
1. Install in the reverse order of removal.
Item 12: C-Pillar Trim Panel Installation Note
1. Be sure the hole on the back of the trim panel is seated over the upper safety belt anchor bolt.
Item 8: Upper B-Pillar Trim Panel Installation Note
1. Be sure the hole on the back of the trim panel is seated over the upper safety belt anchor bolt.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim Panel > Page 9337
Trim Panel: Service and Repair Liftgate Trim Panel
LIFTGATE TRIM PANEL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Page 9338
Torx Bit, Safety Belt Bolt
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9345
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9346
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A626 42
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9347
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9348
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 9349
Keyless Entry Key-Pad: Service and Repair
KEYLESS ENTRY KEYPAD
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Door Glass Top Run Removal Note
1. Position the door glass top run aside to access the door pillar trim panel screws.
INSTALLATION
1. To Install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Application and ID
Keyless Entry Module: Application and ID
For further information regarding the Remote Keyless Entry Module, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair
Keyless Entry Transmitter: Service and Repair
REMOTE TRANSMITTER PROGRAMMING
NOTE: All remote transmitters are programmable and must be set at the same time.
1. Make sure that the anti-theft system is not armed or triggered and key code programming is not
active. 2. Press the driver door lock control switch UNLOCK button. 3. Turn the key from OFF to
ON 8 times within 10 seconds, ending in ON. if the program mode is successfully entered the doors
will lock and
unlock to confirm.
4. Press any button on a remote transmitter, and the doors will lock and then unlock all doors to
confirm that the remote transmitter is programmed.
All remote transmitters must be programmed within 20 seconds. Up to four remote transmitters can
be programmed to the vehicle security module each time programming mode is entered.
5. If the door locks do not respond for any remote transmitter, wait several seconds and press the
button again. If the door locks still fail to respond,
refer to Power Locks.
6. NOTE: Exiting is acknowledged by locking and unlocking the doors if at least one remote
transmitter has been programmed.
Exiting the programming mode is accomplished if one of the following occurring: The key transitions to OFF.
20 seconds have passed since entering programming mode or since the last remote transmitter
was programmed.
- Four remote transmitters have been programmed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear > Page 9361
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear > Page 9362
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Right Rear > Page 9363
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9366
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9367
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9368
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Left Front > Page 9369
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Page 9370
Power Door Lock Actuator: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Page 9371
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Application and ID
Power Door Lock Control Module: Application and ID
For further information regarding the Computer Operated Locks, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Page 9378
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Page 9379
Power Door Lock Switch: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Page 9380
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Page 9381
Power Door Lock Switch: Service and Repair
DOOR LOCK CONTROL SWITCH
NOTE: LH side shown, RH side similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 3: Door Lock Control Switch Removal Note
1. Release the door lock control switch tabs on the switch plate.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Application and ID
Memory Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9390
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9391
Seat Memory Switch: Testing and Inspection
MEMORY SET SWITCH
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, install a new switch; otherwise, return to
the calling Pinpoint Test.
NOTE: Refer to Multimeter User's Manual for testing diodes.
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, install a new switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9395
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9396
Power Mirror Switch: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9397
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9398
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
REMOVAL
1. Remove the front door trim panel.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips
Paint: Technical Service Bulletins Paint - Plastic Bumper/Fascia Service Tips
Article No. 03-10-1
PAINT - PLASTIC BUMPER/FASCIA PARTS - PREPARATION PROCEDURES - SERVICE TIPS
FORD: 2002-2003 CROWN VICTORIA, FOCUS, MUSTANG, TAURUS, ESCAPE, EXPEDITION,
EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, WINDSTAR
LINCOLN: 2002 CONTINENTAL
2002-2003 LS, TOWN CAR, NAVIGATOR
MERCURY: 2002-2003 COUGAR, GRAND MARQUIS, SABLE
2002 VILLAGER 2002-2003 MOUNTAINEER
ISSUE
This article is being written to clarify the proper procedures to prepare plastic fascia parts. Multiple
repair procedures for painting plastic fascia parts are being used in the field that are inconsistent
and may not provide adequate paint adhesion. Paint companies repair procedures are system
specific and do not lend themselves to generic repair procedures.
ACTION
Follow the repair information in this TSB flow chart to perform the initial steps for fascia paint repair
only. After completing the flow chart refer to paint company system recommendations for materials
and mixing instructions for the type of plastic being painted. Also listed in this TSB are some
important service tips to remember when preparing plastic parts for paint application.
SERVICE INFORMATION
For repair information, refer to flow chart Figure 1. Additional Service Tips:
- When washing plastic parts use Motorcraft Detail Wash (ZC-3-A) mixed at a ratio (1 oz. of
ZC-3-A) to 1 gallon of water.
- Use basecoat reducer for a wipe test on coated service parts.
- If the coating (adhesion promoter/primer) shrivels or lifts, remove only that layer of material by
Scotchbrite scuffing or machine sanding. Never remove material to bare plastic substrate, as this
will create more work in order to protect the substrate for application of paint.
- If the adhesion promoter or primer is intact, use a gray Scotchbrite pad and scuff the entire part to
continue preparation steps for normal paint application.
- Follow paint company recommendations for primer or basecoat application.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9404
Paint: Technical Service Bulletins Paint - Approved Paint Materials
Article No. 02-16-7
BODY-PAINT-APPROVED PAINT MATERIALS FOR WARRANTY REPAIRS
FORD: 2003 CROWN VICTORIA, FOCUS, MUSTANG, TAURUS, E SERIES,
ESCAPE, EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT,
EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, WINDSTAR, F-650, F-750
LINCOLN: 2003 CONTINENTAL, LS, TOWN CAR, AVIATOR, NAVIGATOR
MERCURY: 2003 COUGAR, GRAND MARQUIS, SABLE, MOUNTAINEER
ISSUE
Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer
satisfaction. To meet this goal, Ford has tested ten major refinish paint suppliers materials for
warranty repairs. Tests were conducted to paint material specification WSS-M2P100-D for refinish
paint materials.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9405
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9406
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9407
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9408
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9409
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9410
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9411
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9412
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9413
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9414
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9415
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9416
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9417
ACTION
The materials listed in the Figures 1-13, are approved paint systems for refinishing service parts as
well as repair of steel and plastic OEM paint systems.
OTHER APPLICABLE ARTICLES: 98-18-2 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9418
Paint: Technical Service Bulletins Paint - New Polishing Products and Procedures
Article No. 02-16-3
PAINT-NEW POLISHING PRODUCTS-SERVICE PROCEDURES
FORD: 2002-2003 CROWN VICTORIA, ESCORT, FOCUS, TAURUS, ESCAPE,
EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER,
F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750
LINCOLN: 2002-2003 LS, TOWN CAR, NAVIGATOR
MERCURY: 2002-2003 GRAND MARQUIS, SABLE, MOUNTAINEER
ISSUE
Vehicles that have small scratches, mars, dirt, and scuff marks found during pre-delivery or
reconditioning may be repaired without repainting using new Motorcraft polishing products. These
products may also be used effectively for collision damage repairs.
ACTION
Read this TSB in its entirety BEFORE beginning any repairs. Repair as outlined in the following
Service Procedures.
BACKGROUND
The OEM paint system has changed significantly the last 18 months. Previous paint systems
required a number days to be fully cured. The OEM paint system used today cures faster and is
also much harder. The hardness of the OEM system is similar to the hardness of current Refinish
paint system and as a result, a new polishing system is necessary. These products have been
tested on all Ford Motor Company OEM paint finishes and all Major Refinish paint brands. The
system has significantly better results than all other products tested for OEM and Refinish paint
systems.
NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS IS MANDATORY ON ALL
REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, FIELD
SERVICE ACTIONS, CUSTOMER SATISFACTION PROGRAMS, TSB'S OR OTHER COMPANY
PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A
WARRANTY OR ESP/ESC, OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE, (I.E.,
EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE:
ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL
PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL.
SERVICE PROCEDURE
1. Make sure the area to be polished is clean and free of paint sealants and waxes. 2. To remove
dirt nibs, runs, or sags, sand the surface with a D.A. sander or by hand with P1500 grit sandpaper.
3. Apply the Motorcraft ZC-39-B backing pad to dual action sander. 4. Apply the Motorcraft
polishing disc (ZC-39-A kit) to the D.A. sander.
NOTE MAKE SURE THE POLISHING DISC IS CENTERED EXACTLY ON THE BACKING PAD,
OR "WILD SCRATCHES" MAY OCCUR.
5. Dampen the polishing disc with water from a spray bottle before use. 6. Damp polish the repair
area until the dirt, mar, etc. has been removed. The surface should now be semi-polished.
NOTE IF THE IMPERFECTION CANNOT BE REMOVED WITH THE POLISHING DISC, HAND
SAND WITH FINE SAND PAPER IN A STEP PROCESS (I.E. 600 GRIT, 1200 GRIT, 1500 GRIT).
THE POLISHING DISC WILL ONLY REMOVE 1500 GRIT SCRATCHES AND HIGHER.
7. To remove the sand scratches and also remove swirl marks, install a foam-polishing pad onto a
buffer. 8. Apply a small amount of the Motorcraft Finish Enhancement Compound on the foam pad
for the first time of pad use. Do not use a wool pad with
this product.
9. Move the pad around in a 2 foot area to spread out the material, then start up the buffer.
Recommended speed is 1750 rpm. Apply medium
pressure and let the polisher do the work. Verify the imperfection has been removed. If not, repeat
Step 9 until complete.
10. Wipe the repair area with a detailing cloth to complete the
repair.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9419
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes
Paint: Application and ID Paint Codes
The Vehicle Certification Label (VC) is located on the left-hand front door jamb.
The first set of code numbers list the primary body color, the second set of code numbers list the
lower body or two-tone paint code (if applicable).
The following lists the exterior paint codes:
Primary body color codes
- C2 Gold Ash Metallic
- D2 Moss Green
- G2 Redfire
- JP Silver Birch Metallic
- L2 True Blue Pearl
- LD Medium Wedgewood Blue
- P5 Aspen Green Metallic
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9422
- UA Ebony
- YZ Oxford White
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9423
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9424
Paint: Application and ID DSO Fleet Color Codes
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9425
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9426
Paint: Application and ID Explorer/Mountaineer Paint Code Information
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Application and ID
Keyless Entry Module: Application and ID
For further information regarding the Remote Keyless Entry Module, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Application and ID
Memory Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Module >
Component Information > Application and ID
Pedal Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Application and ID
Power Door Lock Control Module: Application and ID
For further information regarding the Computer Operated Locks, please refer to Body Control
Module / Central Security Module (CSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Application and ID
Power Seat Control Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations > Driver Side Front
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Locations > Driver Side Front > Page 9447
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Passenger Side Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Passenger Side Front > Page 9450
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 04-4-5 > Mar > 04 > Body - Roof
Rack Side Rail Paint Peeling
Roof Rack Frame: Customer Interest Body - Roof Rack Side Rail Paint Peeling
Article No. 04-4-5
03/08/04
BODY - TRIM - PAINT PEEL-OFF - ROOF RACK SIDE RAIL
FORD: 2002-2004 EXPLORER
MERCURY: 2002-2004 MOUNTAINEER
ISSUE
Some 2002-2004 4DR Explorer and Mountaineer vehicles may exhibit paint peel on either roof rack
side rail.
ACTION
New service parts are now available to replace either affected side of the roof rack. Order Service
Kit 4L2Z-7855128-AA (RH) or 4L2Z-7855129-AA (LH). Refer to the following Service Procedure for
installation.
SERVICE PROCEDURE
NOTE
THE PROCEDURE IS THE SAME FOR RIGHT OR LEFT HAND SIDE. SEE (FIGURE 1) FOR
EXPLODED VIEW OF ASSEMBLY.
1. Remove front, center, and rear side rail caps by spreading apart from inboard side, and prying
outboard.
2. If equipped with crossbows, support unfastened end of crossbow to prevent damage to roof
panel. Remove both front and rear T-20 TORX head crossbow fasteners which are threaded into
the side rail.
3. Remove six (6) Phillips head screws which fasten rail to roof panel, two (2) each at front, center,
and rear.
4. Remove side rail(s).
5. Remove rubberized gasket at base of each attachment point, front, center and rear.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 04-4-5 > Mar > 04 > Body - Roof
Rack Side Rail Paint Peeling > Page 9460
6. Remove two (2) cargo tie-downs for each rail replaced, and transfer to new side rail.
7. Reverse procedures to install, torque side rail and crossbow fasteners to 3.2 +/- 0.3 N.m (28 +/2.5 lb-in).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040405A Replace Roof Rack Side 0.4 Hr.
Rail (One Rail)
040405B Replace Roof Rack Side 0.7 Hr.
Rails (Both Rails)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7855100 70
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 04-4-5 > Mar > 04 >
Body - Roof Rack Side Rail Paint Peeling
Roof Rack Frame: All Technical Service Bulletins Body - Roof Rack Side Rail Paint Peeling
Article No. 04-4-5
03/08/04
BODY - TRIM - PAINT PEEL-OFF - ROOF RACK SIDE RAIL
FORD: 2002-2004 EXPLORER
MERCURY: 2002-2004 MOUNTAINEER
ISSUE
Some 2002-2004 4DR Explorer and Mountaineer vehicles may exhibit paint peel on either roof rack
side rail.
ACTION
New service parts are now available to replace either affected side of the roof rack. Order Service
Kit 4L2Z-7855128-AA (RH) or 4L2Z-7855129-AA (LH). Refer to the following Service Procedure for
installation.
SERVICE PROCEDURE
NOTE
THE PROCEDURE IS THE SAME FOR RIGHT OR LEFT HAND SIDE. SEE (FIGURE 1) FOR
EXPLODED VIEW OF ASSEMBLY.
1. Remove front, center, and rear side rail caps by spreading apart from inboard side, and prying
outboard.
2. If equipped with crossbows, support unfastened end of crossbow to prevent damage to roof
panel. Remove both front and rear T-20 TORX head crossbow fasteners which are threaded into
the side rail.
3. Remove six (6) Phillips head screws which fasten rail to roof panel, two (2) each at front, center,
and rear.
4. Remove side rail(s).
5. Remove rubberized gasket at base of each attachment point, front, center and rear.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 04-4-5 > Mar > 04 >
Body - Roof Rack Side Rail Paint Peeling > Page 9466
6. Remove two (2) cargo tie-downs for each rail replaced, and transfer to new side rail.
7. Reverse procedures to install, torque side rail and crossbow fasteners to 3.2 +/- 0.3 N.m (28 +/2.5 lb-in).
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
040405A Replace Roof Rack Side 0.4 Hr.
Rail (One Rail)
040405B Replace Roof Rack Side 0.7 Hr.
Rails (Both Rails)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7855100 70
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
View 151-65
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9474
Sunroof / Moonroof Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Early Build
Sunroof / Moonroof Switch: Testing and Inspection Early Build
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Early Build > Page 9477
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Early Build > Page 9478
Sunroof / Moonroof Switch: Testing and Inspection Late build
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Early Build > Page 9479
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Page 9480
Sunroof / Moonroof Switch: Service and Repair
ROOF OPENING PANEL CONTROL SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 3: Roof Opening Panel Control Switch Removal Note
1. Disengage the clips and remove the switch from the overhead console.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise
Sunroof / Moonroof Frame: Customer Interest Body - Moonroof Squeak or Rattle Noise
TSB 05-3-4
02/21/05
MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer
4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise
coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail
assembly. A new corner insert is now available to correct the condition (Figure 2).
ACTION The corner inserts are located in both front corners of the moonroof track and can be
accessed by cycling the moonroof glass to the full open position. The original corner insert design
had snap tabs that may break off during installation, creating a rattle condition. Replace both of the
original inserts and remove any broken tabs left in the track. Refer to the following Service
Procedure.
SERVICE PROCEDURE
1. Open the moonroof to the full open position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9489
2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver
and inspect the snap tabs (Figures 1 and 2).
3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose
debris (Figure 3).
4. Install a new corner insert on both sides (Figure 4).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame:
> 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9490
OPERATION DESCRIPTION TIME
050304A 2001-2003 Explorer Sport, 0.3Hr.
2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator:
Replace Both Of The Moonroof Corner Inserts
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502B36 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise
Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Moonroof Squeak or Rattle Noise
TSB 05-3-4
02/21/05
MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR
FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer
4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise
coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail
assembly. A new corner insert is now available to correct the condition (Figure 2).
ACTION The corner inserts are located in both front corners of the moonroof track and can be
accessed by cycling the moonroof glass to the full open position. The original corner insert design
had snap tabs that may break off during installation, creating a rattle condition. Replace both of the
original inserts and remove any broken tabs left in the track. Refer to the following Service
Procedure.
SERVICE PROCEDURE
1. Open the moonroof to the full open position.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9496
2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver
and inspect the snap tabs (Figures 1 and 2).
3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose
debris (Figure 3).
4. Install a new corner insert on both sides (Figure 4).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof /
Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9497
OPERATION DESCRIPTION TIME
050304A 2001-2003 Explorer Sport, 0.3Hr.
2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator:
Replace Both Of The Moonroof Corner Inserts
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502B36 01
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Application and ID
Memory Positioning Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9506
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9507
Seat Memory Switch: Testing and Inspection
MEMORY SET SWITCH
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, install a new switch; otherwise, return to
the calling Pinpoint Test.
NOTE: Refer to Multimeter User's Manual for testing diodes.
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, install a new switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Application
and ID
Power Seat Control Module: Application and ID
NOTE: ONLY when the vehicle is equipped with the programmable memory option.
For further information regarding this component please refer to Body Control Module / Driver Seat
Module (DSM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left
Power Seat Motor: Diagrams Left
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left >
Page 9515
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left >
Page 9516
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Left
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Left >
Page 9521
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left
Power Seat Switch: Diagrams Left
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left >
Page 9524
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Left
Power Seat Switch: Testing and Inspection Left
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Left > Page 9527
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Left > Page 9528
Power Seat Switch: Testing and Inspection Right
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Left > Page 9529
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions >
Technician Safety Information
Seat Cushion: Technician Safety Information
WARNING:
- The safety belt pretensioner is a pyrotechnic device. Never probe a pretensioner electrical
connector. Doing so could result in pretensioner or air bag deployment and could result in personal
injury.
- 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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).
- To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions
in the supplemental restraint system (SRS) deactivation/reactivation procedure.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and
instructions in the seat removal and installation procedure.
- 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions >
Technician Safety Information > Page 9534
Seat Cushion: Vehicle Damage Warnings
CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the hook
and loop strip can be torn from the seat cushion foam pad.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat
Seat Cushion: Service and Repair Front Seat
FRONT SEAT CUSHION
Special Tool(s)
SPECIAL TOOL(S)
WARNING: The safety belt pretensioner is a pyrotechnic device. Never probe a pretensioner
electrical connector. Doing so could result in pretensioner or air bag deployment and could result in
personal injury.
NOTE: Driver seat is shown, passenger seat is similar.
DISASSEMBLY
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes,
and instructions in the supplemental
restraint system (SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS).
3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the seat
removal and installation procedure.
Remove the front seat.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9537
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9538
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9539
Part 2
4. Disassemble the components in the order listed in the illustration and table. To remove individual
components, carry out only the steps.
Item 21: Cushion Trim Cover Disassembly Note
1. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the
hook and loop strip can be torn from the
seat cushion foam pad.
Separate the hook and loop fasteners.
Item 25: Recliner Roll Pin Disassembly Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9540
1. Drive out the two backrest roll pins and discard them (for installation, use two new roll pins).
Remove the two backrest bolts. Lift off the backrest.
ASSEMBLY
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
assembly portion of this procedure.
To assemble, reverse the disassembly procedure.
2. Connect the battery ground cable.
3. Remove the restraint system diagnostic tool from the vehicle harness side of the front safety belt
buckle pretensioner electrical connector.
4. Connect the front safety belt buckle pretensioner electrical connector. 5. With the restraint
system diagnostic tools installed at the remaining deployable devices, prove out the supplemental
restraint system (SRS). 6. Disconnect the battery ground cable and wait at least one minute.
7. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
notes, and instructions in the
supplemental restraint system (SRS) deactivation/reactivation procedure.
Reactivate the supplemental restraint system (SRS).
8. Connect the battery ground cable.
9. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9541
Seat Cushion: Service and Repair Rear Seat
20 Percent, Second Row
REAR SEAT CUSHION - 20 PERCENT, SECOND ROW
NOTE: Mountaineer seat is shown, Explorer is similar.
DISASSEMBLY
1. Remove the second row, 20 percent seat.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9542
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9543
Part 2
2. Disassemble the components in the order listed in the illustration and table. To remove individual
components, carry out only the steps.
Item 7: Rear Seat 20 Percent Upper Latch Bolts Disassembly Note
1. Remove the release handle cable.
1 Pinch to release the retainer clip.
2 Remove the cable end hook from the retaining hole.
3 Position the cable to the side.
2. Release the seat backrest J-clip. Remove all the staples and lift the material to expose the
backrest nut and bolts.
Item 9: Seat Cushion Trim Cover Disassembly Note
1. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the
hook and loop strip can be torn from the
seat cushion foam pad.
Separate the hook and loop fasteners.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
40 Percent E-Z Entry, Second Row
REAR SEAT CUSHION - 40 PERCENT E-Z ENTRY, SECOND ROW
NOTE: LH seat is shown, RH is similar.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9544
DISASSEMBLY
1. Remove the second row, 40 percent seat.
Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9545
Part 2
2. Disassemble the components in the order listed in the illustration and table. To remove individual
components, carry out only the steps.
Item 1: Rear Seat 40 Percent E-Z Entry Upper Latch Bolts Disassembly Note
1. Release all of the seat backrest J-clips. Slightly raise the backrest trim cover. 2. Remove all of
the staples in the backrest trim cover. 3. Pull the seat backrest material up and remove the four
backrest bolts. Remove the backrest assembly.
Item 9: Cushion Trim Cover Disassembly Note
1. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the
hook and loop strip can be torn from the
seat cushion foam pad.
Separate the hook and loop fasteners.
2. Release the cable from the seat riser and remove the cushion trim cover.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
60 Percent of 60/40 Bench, Second Row
REAR SEAT CUSHION - 60 PERCENT OF 60/40 BENCH, SECOND ROW
DISASSEMBLY
1. Remove the second row, 60 percent seat.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9546
2. Disassemble the components in the order listed in the illustration and table. To remove individual
components, carry out only the steps.
Item 1: Latch Cover Screws Disassembly Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9547
1. NOTE: 40 percent seat shown, 60 percent seat similar.
Release the seat backrest J-clip.
2. Remove all the staples in the backrest support panel.
3. Invert the seat backrest trim cover and foam pad to access the latch cover screws.
4. Remove the two screws and the cover (outboard shown, inboard similar). Detach the seat
backrest material attachment from the latch cover.
Item 5: Rear Seat 60 Percent of 60/40 Upper Pivot Latch Bolt Disassembly Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9548
1. Remove the backrest pivot bolt (inboard side shown, outboard side similar).
Item 7: Cushion Trim Cover Disassembly Note
1. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the
hook and loop strip can be torn from the
seat cushion foam pad.
Separate the hook and loop fasteners.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
40 Percent of 60/40 Bench, Second Row
REAR SEAT CUSHION - 40 PERCENT OF 60/40 BENCH, SECOND ROW
DISASSEMBLY
1. Remove the second row, 40 percent seat.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9549
2. Disassemble the components in the order listed in the illustration and table. To remove individual
components, carry out only the steps.
Item 1: Latch Cover Screws Disassembly Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9550
1. Release the seat backrest J-clip.
2. Remove all the staples in the backrest support panel.
3. Invert the seat backrest trim cover and foam pad to access the latch cover screws.
4. Remove the two screws and the cover (outboard side shown, inboard side similar). Detach the
seat backrest material attachment from the latch
cover.
Item 5: Rear Seat 40 Percent of 60/40 Upper Pivot Latch Bolt Disassembly Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9551
1. Remove the backrest pivot bolt (inboard side shown, outboard side similar).
Item 7: Cushion Trim Cover Disassembly Note
1. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the
hook and loop strip can be torn from the
seat cushion foam pad.
Separate the hook and loop fasteners.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
Third Row
REAR SEAT CUSHION - THIRD ROW
DISASSEMBLY
1. Remove the third row cushion.
2. Disassemble the components in the order listed in the illustration and table.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Front Seat > Page 9552
Item 1: Cushion Trim Cover Disassembly Note
1. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the
hook and loop strip can be torn from the
seat cushion foam pad.
Separate the hook and loop fasteners. Remove the seat trim cover.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions
Seat Heater: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9557
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9558
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9559
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9560
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9561
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9562
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9563
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9564
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9565
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9566
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9567
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9568
Seat Heater: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9569
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9570
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9571
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9572
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9573
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9574
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9575
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9576
Seat Heater: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9577
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9578
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9579
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9580
Seat Heater: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
119-1, System Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9581
119-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9582
119-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9583
119-4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9584
119-5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9585
119-6
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations >
Driver Side Front
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations >
Driver Side Front > Page 9590
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams >
Passenger Side Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams >
Passenger Side Front > Page 9593
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Driver
Side
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Driver
Side > Page 9598
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver
Side
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver
Side > Page 9601
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-4-16 > Mar > 05 > Interior - Front Seat Movement On Accel./Decel.
Seat Track: Customer Interest Interior - Front Seat Movement On Accel./Decel.
TSB 05-4-16
03/07/05
FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Lincoln Aviator vehicles may
exhibit a slight movement from the front seat(s) when accelerating and/or decelerating.
ACTION Install a clip into the seat track to correct the condition. Refer to the following Service
Procedure.
SERVICE PROCEDURE
WARNING
THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) MUST BE DEPOWERED WHEN
PERFORMING THIS REPAIR. THIS SERVICE PROCEDURE MAY REQUIRE HANDLING OF
THE VEHICLES SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND AIR BAG MODULE.
FOLLOW ALL WARNINGS AND STEPS IN WORKSHOP MANUAL SECTION 501-20B
DEPOWERING AND REPOWERING THE SRS.
NOTE
THE SRS MUST BE FULLY OPERATIONAL AND FREE OF FAULTS BEFORE RELEASING THE
VEHICLE TO THE CUSTOMER.
NOTE
DRIVER SEAT IS SHOWN, PASSENGER SEAT IS SIMILAR.
1. Position the seat(s) to allow access to all four (4) mounting bolts.
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in Workshop Manual Section 501-20B.
3. Remove the four (4) seat track bolt covers to expose the seat track bolts.
4. Remove the four (4) seat track mounting bolts.
5. Disconnect the seat electrical connectors.
6. Lift the seat and position it so the bottom of the seat track is exposed.
NOTE
IT IS NOT NECESSARY TO REMOVE THE ENTIRE SEAT FROM THE VEHICLE TO PERFORM
THE CLIP INSTALLATION.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-4-16 > Mar > 05 > Interior - Front Seat Movement On Accel./Decel. > Page 9610
7. Install one (1) seat track clip as shown in (Figure 1) on the right side of track assembly. Position
clip so the tabs are facing the front of the seat.
8. Install the second seat track clip as shown in (Figure 2) on the left side of track assembly.
Position clip so tabs are facing the front of the seat.
NOTE
MAKE SURE THE BATTERY NEGATIVE CABLE IS STILL DISCONNECTED BEFORE
CONTINUING WITH THE REINSTALLATION PORTION OF THIS PROCEDURE.
9. Lower the seat and reconnect the seat electrical connectors.
10. Position the seat and install the four (4) seat track mounting bolts. Torque to 30 lb-ft (40 N.m).
11. Install the four (4) seat track bolt covers.
12. Repower the SRS. Refer to Supplemental Restraint System (SRS) Depowering and
Repowering in Workshop Manual Section 501-20B.
13. Prove out the SRS before releasing the vehicle to the customer. Refer to Workshop Manual
Section 501-20B.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050416A 2002-2005 0.7 Hr.
Explorer/Mountaineer 2003-2005 Aviator: Install Clips Into Seat Track
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
Customer Interest for Seat Track: > 05-4-16 > Mar > 05 > Interior - Front Seat Movement On Accel./Decel. > Page 9611
(Includes Time To Depower/Repower SRS) One Seat (Do Not Use With 61704A, 61704AT)
050416B 2002-2005 1.0 Hr.
Explorer/Mountaineer 2003-2005 Aviator: Install Clips Into Seat Track (Includes Time To
Depower/Repower SRS) Both Seats (Do Not Use With 61704A, 61704AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78618B26 12
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-4-16 > Mar > 05 > Interior - Front Seat Movement On Accel./Decel.
Seat Track: All Technical Service Bulletins Interior - Front Seat Movement On Accel./Decel.
TSB 05-4-16
03/07/05
FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING
FORD: 2002-2005 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2005 Mountaineer
ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Lincoln Aviator vehicles may
exhibit a slight movement from the front seat(s) when accelerating and/or decelerating.
ACTION Install a clip into the seat track to correct the condition. Refer to the following Service
Procedure.
SERVICE PROCEDURE
WARNING
THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) MUST BE DEPOWERED WHEN
PERFORMING THIS REPAIR. THIS SERVICE PROCEDURE MAY REQUIRE HANDLING OF
THE VEHICLES SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND AIR BAG MODULE.
FOLLOW ALL WARNINGS AND STEPS IN WORKSHOP MANUAL SECTION 501-20B
DEPOWERING AND REPOWERING THE SRS.
NOTE
THE SRS MUST BE FULLY OPERATIONAL AND FREE OF FAULTS BEFORE RELEASING THE
VEHICLE TO THE CUSTOMER.
NOTE
DRIVER SEAT IS SHOWN, PASSENGER SEAT IS SIMILAR.
1. Position the seat(s) to allow access to all four (4) mounting bolts.
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in Workshop Manual Section 501-20B.
3. Remove the four (4) seat track bolt covers to expose the seat track bolts.
4. Remove the four (4) seat track mounting bolts.
5. Disconnect the seat electrical connectors.
6. Lift the seat and position it so the bottom of the seat track is exposed.
NOTE
IT IS NOT NECESSARY TO REMOVE THE ENTIRE SEAT FROM THE VEHICLE TO PERFORM
THE CLIP INSTALLATION.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-4-16 > Mar > 05 > Interior - Front Seat Movement On Accel./Decel. >
Page 9617
7. Install one (1) seat track clip as shown in (Figure 1) on the right side of track assembly. Position
clip so the tabs are facing the front of the seat.
8. Install the second seat track clip as shown in (Figure 2) on the left side of track assembly.
Position clip so tabs are facing the front of the seat.
NOTE
MAKE SURE THE BATTERY NEGATIVE CABLE IS STILL DISCONNECTED BEFORE
CONTINUING WITH THE REINSTALLATION PORTION OF THIS PROCEDURE.
9. Lower the seat and reconnect the seat electrical connectors.
10. Position the seat and install the four (4) seat track mounting bolts. Torque to 30 lb-ft (40 N.m).
11. Install the four (4) seat track bolt covers.
12. Repower the SRS. Refer to Supplemental Restraint System (SRS) Depowering and
Repowering in Workshop Manual Section 501-20B.
13. Prove out the SRS before releasing the vehicle to the customer. Refer to Workshop Manual
Section 501-20B.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050416A 2002-2005 0.7 Hr.
Explorer/Mountaineer 2003-2005 Aviator: Install Clips Into Seat Track
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Track: > 05-4-16 > Mar > 05 > Interior - Front Seat Movement On Accel./Decel. >
Page 9618
(Includes Time To Depower/Repower SRS) One Seat (Do Not Use With 61704A, 61704AT)
050416B 2002-2005 1.0 Hr.
Explorer/Mountaineer 2003-2005 Aviator: Install Clips Into Seat Track (Includes Time To
Depower/Repower SRS) Both Seats (Do Not Use With 61704A, 61704AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78618B26 12
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Locations
View 151-14
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Locations > Page 9624
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 9628
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 9629
Power Door Lock Switch: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 9630
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Page 9631
Power Door Lock Switch: Service and Repair
DOOR LOCK CONTROL SWITCH
NOTE: LH side shown, RH side similar.
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 3: Door Lock Control Switch Removal Note
1. Release the door lock control switch tabs on the switch plate.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9635
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9636
Power Mirror Switch: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9637
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9638
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
REMOVAL
1. Remove the front door trim panel.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Left
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Left > Page 9643
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Left > Page 9646
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Left
Power Seat Switch: Testing and Inspection Left
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Left > Page 9649
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Left > Page 9650
Power Seat Switch: Testing and Inspection Right
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Left > Page 9651
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Liftgate Door Lock Switch
View 151-40
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Liftgate Door Lock Switch > Page 9656
View 151-42
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Liftgate Door Lock Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Liftgate Door Lock Switch > Page 9659
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Page 9660
Power Trunk / Liftgate Lock Switch: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Diagrams > Page 9661
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations > Driver Side
View 151-67
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations > Driver Side > Page 9666
View 151-68
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Diagrams > Driver Side
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Diagrams > Driver Side > Page 9669
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 9673
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 9674
Seat Memory Switch: Testing and Inspection
MEMORY SET SWITCH
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, install a new switch; otherwise, return to
the calling Pinpoint Test.
NOTE: Refer to Multimeter User's Manual for testing diodes.
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, install a new switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
View 151-65
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 9678
Sunroof / Moonroof Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Early Build
Sunroof / Moonroof Switch: Testing and Inspection Early Build
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Early Build > Page 9681
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Early Build > Page 9682
Sunroof / Moonroof Switch: Testing and Inspection Late build
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Early Build > Page 9683
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Page 9684
Sunroof / Moonroof Switch: Service and Repair
ROOF OPENING PANEL CONTROL SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 3: Roof Opening Panel Control Switch Removal Note
1. Disengage the clips and remove the switch from the overhead console.
INSTALLATION
1. Install in the reverse order of removal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations
Brake Switch (Cruise Control): Locations
View 151-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page
9693
View 151-26
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Brake
Pedal Position Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Brake
Pedal Position Switch > Page 9696
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Technician Safety Information > Page 9699
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair >
Speed Control Deactivator Switch-With Stability Assist
Brake Switch (Cruise Control): Service and Repair Speed Control Deactivator Switch-With Stability
Assist
SPEED CONTROL DEACTIVATOR SWITCH - WITH STABILITY ASSIST
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Speed Control Deactivator Switch Removal Note
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.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Speed Control Deactivator Switch Installation Note
1. After the deactivator switch is installed, it is necessary to bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair >
Speed Control Deactivator Switch-With Stability Assist > Page 9702
Brake Switch (Cruise Control): Service and Repair Speed Control Deactivator Switch-Without
Stability Assist
SPEED CONTROL DEACTIVATOR SWITCH - WITHOUT STABILITY ASSIST
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Speed Control Deactivator Switch Removal Note
1. Rotate counterclockwise 45 degrees to remove the speed control deactivator switch.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Speed Control Deactivator Switch Installation Note
1. Press the brake pedal and rotate clockwise 45 degrees to install the speed control deactivator
switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations
View 151-17
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 9706
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 9707
Cruise Control Servo: Service and Repair
SPEED CONTROL ACTUATOR
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 4: Speed Control Actuator and Bracket Removal Note
1. Remove the speed control bracket and actuator as an assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair
Cruise Control Servo Cable: Service and Repair
SPEED CONTROL CABLE
NOTE: 4.6L shown (4.OL similar)
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Item 4: Speed Control Cable Installation Note
1. Make sure the tabs on the speed control cable are locked in place and cable is fully seated in
bracket.
Item 6: Speed Control Cable Installation Note
1. Make sure the rubber seal is fully seated onto the speed control cable cap.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed
Control Switch-Without Remote Audio/Climate Controls
Cruise Control Switch: Service and Repair Speed Control Switch-Without Remote Audio/Climate
Controls
SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROLS
REMOVAL
1. Remove the air bag.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed
Control Switch-Without Remote Audio/Climate Controls > Page 9715
Cruise Control Switch: Service and Repair Speed Control Switch-With Remote Audio/Climate
Controls
SPEED CONTROL SWITCH WITH REMOTE AUDIO/CLIMATE CONTROLS
REMOVAL
1. Remove the air bag.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations
Brake Switch (Cruise Control): Locations
View 151-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Page 9720
View 151-26
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Brake Pedal Position Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Brake Pedal Position Switch > Page 9723
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Technician Safety Information > Page 9726
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service and Repair > Speed Control Deactivator Switch-With Stability Assist
Brake Switch (Cruise Control): Service and Repair Speed Control Deactivator Switch-With Stability
Assist
SPEED CONTROL DEACTIVATOR SWITCH - WITH STABILITY ASSIST
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Speed Control Deactivator Switch Removal Note
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.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Speed Control Deactivator Switch Installation Note
1. After the deactivator switch is installed, it is necessary to bleed the brake system.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service and Repair > Speed Control Deactivator Switch-With Stability Assist > Page 9729
Brake Switch (Cruise Control): Service and Repair Speed Control Deactivator Switch-Without
Stability Assist
SPEED CONTROL DEACTIVATOR SWITCH - WITHOUT STABILITY ASSIST
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 2: Speed Control Deactivator Switch Removal Note
1. Rotate counterclockwise 45 degrees to remove the speed control deactivator switch.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Speed Control Deactivator Switch Installation Note
1. Press the brake pedal and rotate clockwise 45 degrees to install the speed control deactivator
switch.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Speed Control Switch-Without Remote Audio/Climate Controls
Cruise Control Switch: Service and Repair Speed Control Switch-Without Remote Audio/Climate
Controls
SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO/CLIMATE CONTROLS
REMOVAL
1. Remove the air bag.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Speed Control Switch-Without Remote Audio/Climate Controls > Page 9734
Cruise Control Switch: Service and Repair Speed Control Switch-With Remote Audio/Climate
Controls
SPEED CONTROL SWITCH WITH REMOTE AUDIO/CLIMATE CONTROLS
REMOVAL
1. Remove the air bag.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9740
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9741
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9742
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9743
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9744
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9745
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9746
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9747
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9748
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9749
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9750
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9751
Audible Warning Device: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9752
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9753
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9754
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9755
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9756
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9757
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9758
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9759
Audible Warning Device: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
66-1, System Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9760
66-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9761
66-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 9762
66-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Page 9763
Audible Warning Device: Description and Operation
PRINCIPLES OF OPERATION
The instrument cluster controls the following warnings and chimes:
- driver or passenger safety belt not fastened warning chime (warning times out)
- key-in-ignition warning (repetitive chime)
- headlamp-on warning (repetitive chime)
- door ajar warning (repetitive chime)
- safety belt warning chime (repetitive chime)
- belt minder warning chime (repetitive chime after a delay and the safety belt chime has
completed)
The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning
chime will sound when the driver or passenger safety belt is not fastened and the key is turned
from the OFF/LOCK or ACC to the RUN or START position.
The safety belt warning chime will stop sounding when the safety belt is fastened, when the key is
switched from the RUN or START to the OFF/LOCK or ACC position, or when the chime has
sounded for approximately six seconds.
The safety belt warning chime inputs are:
- ignition switch START position, voltage applied on START circuit 489 (PK/BK)
- ignition switch RUN position, voltage applied on RUN circuit 295 (LB/PK)
- driver or passenger safety belt switch data communicated by the restraint control module (RCM)
to the instrument cluster on circuit 1390 (DB)
The safety belt warning lamp along with the chime warns that the safety belt is not fastened. The
safety belt warning lamp will be illuminated when the safety belt is not fastened and the key is
turned from the OFF/LOCK or ACC to the RUN or START position.
The safety belt warning lamp will turn off when the safety belt is fastened, the key is moved from
the RUN or START to the OFF/LOCK or ACC position, or if the lamp is illuminated for
approximately 6 seconds.
The safety belt warning lamp inputs are:
- ignition switch START position, voltage applied on START circuit 489 (PK/BK)
- ignition switch RUN position, voltage applied on RUN circuit 295 (LB/PK)
- driver or passenger safety belt switch data communicated by the RCM to the instrument cluster
on circuit 1390 (DB)
NOTE: The belt minder is configurable. To configure without using a diagnostic tool, refer to Belt
Minder Deactivating/Activating.
The belt minder feature supplements the current safety belt warning function. The belt minder is
enabled after the current safety belt warning is complete. The belt minder reminds the driver that
the driver or passenger safety belt is unbuckled by intermittently sounding a chime and illuminating
the safety belt warning lamp in the instrument cluster. While activated, the belt minder alternates
the chime and indicator from on for 6 seconds to off for 30 seconds.
The door ajar warning chime warns that a door is not fully closed. The chime will sound when any
door or the liftgate becomes ajar while the key is in the RUN position.
The door ajar warning indicator warns that a door is not fully closed. The door ajar warning
indicator will be illuminated when any door or the liftgate initially becomes ajar while the key is in
the RUN or START position.
The door ajar warning indicator will turn off when all doors and the liftgate are closed, or the key is
turned to the OFF/LOCK or ACC position.
The door ajar warning lamp/chime inputs are:
- ignition switch START position, voltage applied on START circuit 489 (PK/BK)
- ignition switch RUN position, voltage applied on RUN circuit 295 (LB/PK)
- door ajar data communicated by the vehicle security module to the instrument cluster on the UBP
communication circuit 693 (OG)
The key-in-ignition warning chime warns that the key is still in the ignition when the driver door is
ajar. The key-in-ignition warning chime will sound when the driver door is ajar, the ignition switch is
in the OFF/LOCK or ACC position and the key is in the ignition.
The key-in-ignition warning chime will stop sounding when the driver door is closed, the key is
removed from the ignition, or if the key is turned to the RUN position.
The key-in-ignition warning chime inputs are:
- ignition switch START position, no voltage on START circuit 489 (PK/BK)
- ignition switch RUN position, no voltage on RUN circuit 295 (LB/PK)
- key-in-ignition switch circuit 1414 (LG/VT), voltage applied with key in ignition
The headlamp on warning chime warns that the headlamps are on when the driver door is ajar and
the key is removed from the ignition. The headlamps
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Page 9764
on warning chime will sound if the driver door is ajar, the headlamp switch is in the PARK or HEAD
position, and the ignition switch is in the OFF/LOCK position with the key out.
The headlamp on warning chime will stop sounding when any one of the above conditions are
removed. The headlamp on warning chime inputs are:
- ignition switch START position, no voltage on START circuit 489 (PK/BK)
- ignition switch RUN position, no voltage on RUN circuit 295 (LB/PK)
- key-in-ignition switch circuit 1414 (LG/VT), no voltage applied with key removed from the ignition
- voltage applied on the instrument illumination circuit 235 (RD/BK)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9769
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9770
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9771
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9772
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9773
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9774
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9775
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9776
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9777
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9778
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9779
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9780
Cigarette Lighter: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9781
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9782
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9783
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9784
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9785
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9786
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9787
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9788
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9789
Cigarette Lighter: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
44-1
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Page 9793
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment
Compass: Adjustments Compass Zone Adjustment
COMPASS ZONE ADJUSTMENT
With Message Center
1. NOTE: The compass zone setting is preset from the factory to Zone 8.
Determine which magnetic zone you are in for your geographic location.
2. Turn the ignition key to the START position. 3. Press the message center switch INFO button
until the compass information is displayed. 4. Press the RESET button until RESET FOR ZONE is
displayed in the message center display.
5. NOTE: To exit the compass zone adjustment mode before carrying out a compass zone
adjustment, press the INFO button.
Press the RESET button until SETUP ZONE XX is displayed in the message center display.
6. Press the SETUP button repeatedly until the correct zone setting for your geographic location is
displayed. 7. Press the RESET button to exit the zone setting mode and lock your individual zone.
Without Message Center
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 9796
1. NOTE: The compass zone setting is preset from the factory to Zone 8.
Determine which magnetic zone you are in for your geographic location.
2. Turn the ignition key to the ON position.
3. Locate the compass module at the base of the mirror.
4. Insert a paperclip into the small hole on the bottom of the sensor module. Press and hold until
ZONE and the current zone setting (1-15) appear in
the instrument cluster display, and release.
5. Press on the paperclip repeatedly to cycle through the possible zone settings until the setting for
your geographic location is displayed. 6. Release pressure on the paperclip to exit the zone setting
mode. After approximately five seconds the display will report the direction and the zone
will be set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 9797
Compass: Adjustments Vehicle Demagnetizing
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. Carry out the Compass Zone Adjustment procedure. 3. Carry out the Compass Calibration
Adjustment procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment > Page 9798
Compass: Adjustments Compass Calibration
COMPASS CALIBRATION
With Message Center
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects
or structures. Switch off all non-essential
electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all
doors are closed.
Start the vehicle.
2. Press the RESET button until RESET FOR CAL is displayed in the message center display.
3. NOTE: To exit the calibration adjustment mode before carrying out a compass adjustment, press
the INFO button.
Press the RESET button until CIRCLE SLOWLY TO CAL is displayed in the message center
display.
4. Slowly drive the vehicle in a circle no more than five times at no more than 5 km/h (3 mph) until
CIRCLE SLOWLY TO CAL changes to
CALIBRATION COMPLETED in the message center.
Without Message Center
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects
or structures. Switch off all non-essential
electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all
doors are closed.
Start the vehicle.
2. Locate the compass module at the base of the mirror. Press the button located on the compass
sensor module gently until CAL is displayed in the
compass display and release the button.
3. NOTE: To exit the CAL mode before carrying out a compass adjustment, turn the ignition switch
to the OFF position.
Press the button until CIRCLE SLOWLY is displayed in the compass display.
4. NOTE: If the CIRCLE SLOWLY display 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.
Slowly drive the vehicle in a circle no more than five times at no more than 5 km/h (3 mph) until
CIRCLE SLOWLY changes to CAL in the compass display.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Technician Safety Information > Page 9804
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9807
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9808
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9809
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9810
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9811
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9812
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9813
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9814
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9815
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9816
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9817
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9818
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9819
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9820
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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9821
10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9822
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9823
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9824
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9825
- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9826
10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9827
12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9828
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9829
Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9830
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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9831
3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9832
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9833
11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9834
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9835
All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9836
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9837
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9838
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9839
13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9840
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9841
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9842
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9843
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Page 9844
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch
View 151-43
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 9849
View 151-42
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 9850
Door Switch: Locations Door Ajar Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 9851
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 9852
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Ajar Switch > Page 9853
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch > Page 9856
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch > Page 9857
Door Switch: Diagrams Door Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Ajar Switch > Page 9858
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
View 151-28
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 9862
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > Information and Message Center
Driver/Vehicle Information Display: Description and Operation Information and Message Center
INFORMATION AND MESSAGE CENTER
The message center is a green vacuum fluorescent, fixed format display, integrated into the lower
RH corner of the instrument cluster. The message center functions are controlled by the message
center switches. The message center displays important vehicle information by constantly
monitoring different vehicle systems. The message center will notify the driver of a potential vehicle
problem by displaying a warning message pertaining to the system in which a fault has been
detected.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > Information and Message Center > Page 9865
Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It
Work?)
PRINCIPLES OF OPERATION
The message center electronic functions use both hardwired, standard corporate protocol (SCP),
and UART based protocol (UBP) communication networks to transmit and receive information. It is
very important to understand:
- where the input (command) originates from.
- all the information (messages) necessary in order for a feature to operate.
- which module(s) receive(s) the input or command message.
- does the module which received the input (message) control the output of the feature, or does it
output a message over the SCP or UBP communication network to another module?
- which module controls the output of the feature.
The message center provides the following features:
- information displays
- setup displays
- warning messages
- system check messages
The message center information can be selected through a set of three switches:
- INFO
- SETUP
- RESET
Tire Pressure Monitoring System
The following messages may appear if the vehicle is equipped with a tire pressure monitoring
system: CHECK TIRE PRESSURE
- CHECK SPARE TIRE PRESSURE
- WARNING TIRE VERY LOW
- TIRE PRESSURE SYSTEM OFF
- TIRE PRESSURE SYSTEM FAULT
- TIRE PRESSURE SENSOR FAULT
General information on these messages may also be found in the owner literature.
Information Displays
The information displays are non-timed modes. The selected mode remains on until the driver
presses a message center switch to change the mode or it is overridden by another mode. The
information display modes are: odometer
- trip odometer
- compass
- distance to empty
- average fuel economy
Setup Displays
The setup displays are timed modes and terminate after a finite interval. The setup display modes
are: language
- English/metric units
- system check
- oil life status
- oil life in xx%
- charge system status
- oil pressure status
- engine temp status
- washer fluid level
- brake fluid level
- fuel level status
- distance to empty
- tire warning
Every 180 days or 8,000 km (5,000 miles) the oil life display in the message center SYSTEM
CHECK will decrease gradually from 100% to 0%. At 5% oil life, the CHANGE OIL SOON warning
indicator will illuminate. At 0% oil life, the OIL CHANGE REQUIRED warning indicator will
illuminate. Oil life status is continually displayed in the SYSTEM CHECK portion of the message
center and oil life warnings appear if oil life is low.
Warning Messages
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > Information and Message Center > Page 9866
The warning messages are single cycle, non-resettable and repetitive warning messages. The
single cycle warning messages are: CHANGE OIL SOON
- OIL CHANGE REQUIRED
- LOW WASHER FLUID LEVEL
- LOW BRAKE FLUID LEVEL
The single cycle warning messages will display once whenever the key is turned to ON or a fault
occurs in a system and can be cleared by pressing the RESET button.
The repetitive warning messages are: CHECK CHARGING SYSTEM
- TRANSMISSION OVERHEATED
- CHECK TRANSMISSION
- LOW FUEL LEVEL
- LOW OIL PRESSURE
- CHECK ENGINE TEMPERATURE
- CHECK TIRE PRESSURE
- CHECK FUEL CAP
The repetitive warning messages are displayed at a fixed interval whenever the key is turned ON or
is in the ACC position. To remove a repetitive warning message, press the RESET button. The
message will only reoccur after 10 minutes or until the warning condition is corrected.
The tire pressure warning is displayed whenever the tire pressure module receives a signal from a
tire pressure sensor, indicating that the tire pressure is out of range.
The non-resettable warning messages will display whenever the key is turned to ON and a fault
occurs in a system. The fault must be corrected to clear the non-resettable warning messages.
The non-resettable warning messages are: DOOR AJAR
- BACKUP AID
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
NOTE:
- A new instrument cluster must be reconfigured.
- When installing a new instrument cluster, it is necessary to contact the Instrument Cluster
Program.
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link
connector and select the vehicle to be tested from the diagnostic tool
menu. If the diagnostic 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 position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
- SCP+ or SCP- circuit fault; all electronic control units no response/not equipped, refer to Module
Communications Network (Information Bus).
- No response/not equipped for the instrument cluster, GO to Pinpoint Test G. See: Testing and
Inspection/Instrument Cluster/Pinpoint Tests/Test G
- System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the
continuous DTCs and carry out self-test diagnostics for the instrument cluster.
7. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic
Trouble Code (DTC) Index to continue diagnostics.
See: Diagnostic Trouble Code Descriptions
8. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
See: Symptom Related Diagnostic Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9869
DTC Index B1205 - U2013
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9870
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart, Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9871
Symptom Chart, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9872
Driver/Vehicle Information Display: Pinpoint Tests
Compass Sensor Module C909
Instrument Cluster C220a
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9873
Instrument Cluster C220b
Message Center Switch C253
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9874
Washer Fluid Level Switch C138
Tests AJ
PINPOINT TEST AJ: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY
Test AJ1
Normal Conditions
The message center display is located in the instrument cluster The instrument cluster odometer
display and message center display are contained in the same window.
Possible Causes
- instrument cluster
- message center switch
Tests AK
PINPOINT TEST AK: THE COMPASS IS INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9875
Test AK1-AK2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9876
Test AK3
Normal Conditions
The compass sensor module receives power from circuit 1003 (GY/YE) and is grounded through
circuit 1203 (BK/LB). The compass sensor module communicates vehicle direction to the
instrument cluster to be displayed in the message center. The compass sensor module utilizes
circuit 702 (WH/BK) and circuit 703 (WH/OG) to communicate to the instrument cluster.
Possible Causes
- circuit 1003 (GY/YE) open
- circuit 1203 (BK/LB) open
- circuit 702 (WH/BK) open or short
- circuit 703 (WH/OG) open or short
- compass sensor module
Tests AL
PINPOINT TEST AL: THE COMPASS IS INACCURATE
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9877
Test AL1-AL3
Normal Operation
The compass sensor module communicates vehicle direction to the instrument cluster to be
displayed in the message center.
Possible Causes
- compass sensor module
- vehicle is magnetized
Tests AM
PINPOINT TEST AM: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
Test AM1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9878
Test AM2-AM4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9879
Test AM5
Normal Operation
The message center switch assembly uses circuits 231 (BK/YE) and 1411 (GY/OG) to
communicate the requested switch function to the message center.
Possible Causes
- circuit 231 (BK/YE) open or shorted to ground
- circuit 1411 (GY/OG) open or shorted to ground
- instrument cluster
- message center switch
Tests AN
PINPOINT TEST AN: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW WASHER
FLUID LEVEL DISPLAY
Test AN1
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9880
Test AN2-AN4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9881
Test AN5
Normal Conditions
The washer fluid level switch circuit 81 (RD/LG) is open when the washer fluid level is high. When
the washer fluid level is low, the switch will close circuit 81 (RD/LG) with the ground circuit 1203
(BK/LB) to signal the message center to indicate the washer fluid level is low.
Possible Causes
- circuit 1203 (BK/LB) open
- circuit 81 (RD/LG) open or short
- instrument cluster
- washer fluid level switch
Tests AO
PINPOINT TEST AO: THE INDICATOR DOES NOT OPERATE CORRECTLY - DOOR AJAR
DISPLAY
Test AO1-AO3
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
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Test AO4-AO5
Normal Conditions
The vehicle security module communicates the door ajar status to the message center over the
UART based protocol (UBP) communication network, circuit 693 (OG).
Possible Causes
- door ajar switch
- instrument cluster
- vehicle security module
Tests AP
PINPOINT TEST AP: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW FUEL LEVEL
DISPLAY
Test AP1-AP2
Normal Conditions
The instrument cluster communicates the fuel level status to the message center.
Possible Causes
- fuel pump module
- instrument cluster
Tests AQ
PINPOINT TEST AQ: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW BRAKE
FLUID LEVEL DISPLAY
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Test AQ1-AQ2
Normal Conditions
The instrument cluster communicates the brake fluid level status to the message center.
Possible Causes
- brake fluid level switch
- instrument cluster
Tests AR
PINPOINT TEST AR: THE INDICATOR DOES NOT OPERATE CORRECTLY - LOW OIL
PRESSURE DISPLAY
Test AR1-AR2
Normal Conditions
The instrument cluster communicates the oil pressure status to the message center.
Possible Causes
- engine oil pressure switch
- instrument cluster
Tests AS
PINPOINT TEST AS: THE INDICATOR DOES NOT OPERATE CORRECTLY - CHECK ENGINE
TEMPERATURE
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Test AS1-AS2
Normal Conditions
The instrument cluster communicates the engine temperature status to the message center.
Possible Causes
- engine oil pressure switch
- instrument cluster
Tests AT
PINPOINT TEST AT: THE INDICATOR DOES NOT OPERATE CORRECTLY - BACK-UP AID
Test AT1-AT3
Normal Conditions
The parking aid module communicates the backup aid status to the message center using
hardwired circuit 1435 (VT/OG) and ISO communication circuit 70 (LB/WH).
Possible Causes
- parking aid module
- instrument cluster
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Component Information > Testing and Inspection > Page 9885
Driver/Vehicle Information Display: Service and Repair
MESSAGE CENTER
REMOVAL
1. Remove the instrument cluster center finish panel.
2. Remove the components in the order indicated in the illustration and table.
Item 2: Message Center Switch Removal Note
1. Press the retaining tabs to remove the message center switch.
INSTALLATION
1. To install, reverse the removal procedure.
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Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 9898
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 9899
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 9900
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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Empty/MIL ON/DTC's > Page 9901
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 9902
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to
Empty/MIL ON/DTC's > Page 9903
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 9909
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 9910
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 9911
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 9912
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 9913
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-2-12 > Feb > 06 > Instruments - Fuel
Gauge Drops to Empty/MIL ON/DTC's > Page 9914
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9923
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9924
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9925
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9926
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9927
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-2-12 > Feb > 06 > Instruments Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9928
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9934
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9935
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9936
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9937
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-2-12 > Feb > 06 >
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9938
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 9939
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Technician Safety Information
Air Bag(s) Arming and Disarming: Technician Safety Information
WARNING:
- If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and
restraint system diagnostic tools must be installed.
The air bag restraint system diagnostic tools must be removed and the air bag modules
reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in
possible personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on a safety canopy module. Doing so can result in safety canopy
deployment.
- To avoid accidental deployment and possible personal injury, the RCM backup power supply
must be depleted before repairing or replacing any front or side air bag 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.
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 side impact sensors (if equipped) are located at or near the base of the B-pillars and C-pillars.
- To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at
the beginning of the deactivation procedure.
- 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.
- 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 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.
- Any time the safety canopy has deployed, the headliner, and all A, B and C pillar upper trim
panels and attaching hardware must be replaced along with any other damaged components and
hardware. Failure to do so may result in personal injury in the event of a safety canopy deployment.
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Arming and Disarming > System Information > Service Precautions > Technician Safety Information > Page 9945
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
CAUTION:
- Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor
from the safety canopy electrical connector.
- The clockspring electrical connectors are unique and cannot be reversed when connected to the
driver air bag module. Match the electrical connector key to the keyway in the driver air bag
module. Do not force the electrical connectors into the driver air bag module.
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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
Procedures For Repair
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
SPECIAL TOOL(S)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
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.
- 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.
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9948
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 air bag system must be deactivated.
- Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
- Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with
a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic
tools must be installed in the seat side air bag electrical connectors. The restraint system
diagnostic tools must be removed prior to operating the vehicle over the road.
- After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
3. Remove the two driver air bag module bolts (one shown).
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4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9950
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
11. Disconnect the RH safety canopy electrical connector.
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9951
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats
13. Connect the battery ground cable.
All vehicles
14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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 impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
16. From under the front RH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9952
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles
21. From under the front LH seat, push in to release the tab and disconnect the safety belt buckle
pretensioner electrical connector.
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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 9953
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). See: Prove Out
Procedure
25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9954
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9955
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
8. From under the front RH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9956
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies
10. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9957
13. Position the RH C-pillar trim panel.
1 With the book aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats
15. Connect the battery ground cable.
All vehicles
16. Position the front seats rearward.
Vehicles with power seats
17. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9958
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9959
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS). See: Prove Out Procedure
Vehicles with safety canopies
27. Check the active restraints for correct operation.
Procedures For Repair Operations
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9960
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment.
- 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.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central
junction box (CJB), located below the LH side of the instrument panel, remove the restraints control
module (RCM) fuse F2.19
(10A) from the CJB.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9961
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 or
RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
The side impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least 1 minute.
7. Remove the 2 steering wheel back cover plugs (one shown).
8. Remove the 2 driver air bag module bolts (one shown).
9. Remove the driver air bag module.
1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9962
10. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
11. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
12. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
14. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9963
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Vehicles with safety canopies
15. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
16. Disconnect the RH safety canopy electrical connector.
17. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9964
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
All vehicles 21. Install the RCM fuse F2.19 (10A) to the CJB. 22. Connect the battery ground cable.
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warning, cautions, and
noted at the beginning of the deactivation procedure.
All vehicles 1. Remove the RCM fuse F2.19 (10A) from the CJB. 2. Disconnect the battery ground
cable and wait at least 1 minute.
Vehicles with safety canopies
3. Remove the restraint system diagnostic tool from the LH safety canopy vehicle harness electrical
connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9965
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9966
- Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with safety canopies
8. Remove the restraint system diagnostic tool from the RH safety canopy vehicle harness
electrical connector.
9. Connect the RH safety canopy electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9967
10. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
11. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9968
12. Push in, seating the retainers.
- After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector.
14. Connect the passenger air bag module electrical connector. 15. Close the glove compartment.
16. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9969
17. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
18. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 9 Nm (80 lb-in).
19. Install the 2 steering wheel back cover plugs (1 shown).
20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
remove could result in injury and possible violation of vehicle safety standards.
Make sure all restraint system diagnostic tool(s) that may have been installed during the repair
have been removed from the vehicle and all SRS components are connected.
21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.19 (10A) to the CJB.
23. 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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9970
Connect the battery ground cable.
24. 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 6 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and
any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Vehicles with safety canopies
25. Check the active restraints for correct operation.
Deactivation
Special Tool(s)
Special Tool(s)
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
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.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9971
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: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when
repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety
belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result
in pretensioner or air bag deployment and could result in personal injury.
WARNING: Never probe the connectors on the safety canopy module. Doing so can result in safety
canopy deployment.
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: 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 air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag
(if equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag
with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped
with a seat side air bag the seat must be removed from the vehicle and the restraint system
diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint
system diagnostic tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, 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.
All vehicles
1. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
2. Remove the two steering wheel back cover plugs (one shown).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9972
3. Remove the two driver air bag module bolts (one shown).
4. Remove the driver air bag module.
1 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
2 Release the two retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector
before disconnecting.
3 Disconnect the horn switch electrical connector.
4 Remove the driver air bag module.
5. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
6. Push in on the glove compartment sides, releasing the stops and lowering it out of the way.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9973
7. Through the glove compartment opening, release the tab and disconnect the passenger air bag
module electrical connector.
8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector.
Vehicles without safety canopies
9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy electrical
connector.
If the safety canopy bridge resistor is removed an open circuit fault will be generated by the
restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety
canopy electrical connector, a low resistance fault will be generated by the RCM.
Vehicles with safety canopies 10. Remove the RH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9974
11. Disconnect the RH safety canopy electrical connector.
12. Attach the restraint system diagnostic tool to the vehicle harness side of the RH safety canopy
electrical connector.
Vehicles with power seats 13. Connect the battery ground cable.
All vehicles 14. Move and tilt the front seats to their highest and most forward position.
Vehicles with power seats
15. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute
All vehicles 16. From under the front RH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9975
17. Attach the restraint system diagnostic tool to the front RH seat safety belt buckle pretensioner
floor electrical connector.
Vehicles with safety canopies 18. Remove the LH C-pillar trim panel.
1 Pull out and release the retaining clips.
2 Pull out and release the retainer.
3 Lower the door opening weatherstrip, slide the C-pillar trim panel up, releasing the retainers and
remove the C-pillar trim panel.
19. Disconnect the LH safety canopy electrical connector.
20. Attach the restraint system diagnostic tool to the vehicle harness side of the LH safety canopy
electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9976
All vehicles 21. From under the front LH seat, push in to release the tab and disconnect the safety
belt buckle pretensioner electrical connector.
22. Attach the restraint system diagnostic tool to the front LH seat safety belt buckle pretensioner
floor electrical connector. 23. Connect the battery ground cable. 24. With the restraint system
diagnostic tools installed at all deployable devices, prove out the supplemental restraint system
(SRS). 25. Disconnect the battery ground cable and wait at least one minute.
Reactivation
Reactivation
WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions,
and notes at the beginning of the deactivation procedure.
All vehicles
1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
From under the front LH seat, remove the restraint system diagnostic tool from the safety belt
buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9977
2. From under the front LH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the LH safety
canopy vehicle harness electrical connector.
4. Connect the LH safety canopy electrical connector.
5. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and. C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a safety canopy deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the LH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9978
6. Position the LH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
7. Push in on the C-pillar trim panel, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
All vehicles 8. From under the front RH seat, remove the restraint system diagnostic tool from the
safety belt buckle pretensioner floor electrical connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9979
9. From under the front RH seat, connect the safety belt buckle pretensioner electrical connector.
Vehicles with safety canopies 10. Remove the restraint system diagnostic tool from the RH safety
canopy vehicle harness electrical connector.
11. Connect the RH safety canopy electrical connector.
12. WARNING: Any time the safety canopy has deployed, the headliner, and all A, B and C pillar
upper trim panels and attaching
hardware must be replaced along with any other damaged components and hardware. Failure to
do so may result in personal injury in the event of a side air curtain deployment.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Align the RH C-pillar trim panel hook to the opening in the sheet metal. ^
The safety belt shoulder height adjuster and the C-pillar trim panel sliding insert must be at their
most upward position of travel to aid installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9980
13. Position the RH C-pillar trim panel.
1 With the hook aligned to the sheet metal, position the top of the C-pillar trim panel to the sheet
metal. Make sure the safety belt shoulder height adjuster and the C-pillar trim panel sliding insert are at
their most upward position of travel to aid installation.
2 Align and slide down, engaging the front upper trim panel retainer. The C-pillar trim panel sliding insert circular recess must align to the safety belt guide bolt.
3 Align and push in, engaging the front lower trim panel retainer.
14. Push in, seating the retainers.
^ After the C-pillar trim panel is reinstalled, make sure the safety belt shoulder height adjuster
button activation and the vertical movement of the trim panel sliding insert is smooth.
Vehicles with power seats 15. Connect the battery ground cable.
All vehicles 16. Position the front seats rearward.
Vehicles with power seats
17. 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
impact sensors (if equipped) are located at or near the base of the B-pillars and C-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 and wait at least one minute.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9981
All vehicles
18. NOTE: Make sure the battery negative cable is still disconnected before continuing with the
reactivation portion of this procedure.
Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag
module electrical connector.
19. Connect the passenger air bag module electrical connector. 20. Close the glove compartment.
21. Remove the restraint system diagnostic tools from the clockspring electrical connector at the
top of the steering column.
22. Position the driver air bag module to the steering wheel.
1 Connect the horn switch electrical connector.
2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9982
Connect the driver air bag module electrical connectors as noted during removal.
3 Position the driver air bag module to the steering wheel.
23. Install the two driver air bag module bolts (one shown).
24. Install the two steering wheel back cover plugs (one shown). 25. Connect the battery ground
cable.
26. 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.
With all the restraint system diagnostic tools removed, prove out the supplemental restraint system
(SRS).
Vehicles with safety canopies 27. Check the active restraints for correct operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9983
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
AIR BAG RECONNECT CHECKLIST
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All air bag modules connected?
- Safety belt pretensioner connectors connected?
- Restraints control module (RCM) connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 9984
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
PROVE OUT PROCEDURE
Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator
with all SRS components connected or restraint system diagnostic tools installed. The air bag
indicator will light continuously for approximately six seconds and then turn off. If an 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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Page 9985
Special Tool(s)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions
Low Tire Pressure Indicator: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9990
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9991
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9992
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9993
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9994
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9995
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9996
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9997
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9998
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 9999
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10000
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10001
Low Tire Pressure Indicator: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10002
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10003
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10004
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10005
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10006
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10007
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10008
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 10009
Low Tire Pressure Indicator: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
118-1
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) (Figure 17) 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 18).
- 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 Symptom Charts.
- 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.
Malfunction Indicator Lamp (MIL)
CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
Change Oil Soon/Oil Change Required Message
Displayed when the engine oil life remaining is 5 percent or less. When oil life left is between 5%
and 0% the CHANGE OIL SOON message will be displayed. When oil life left reaches 0% the OIL
CHANGE REQUIRED message will be displayed.
An oil change is required whenever indicated by the message center. USE ONLY
RECOMMENDED ENGINE OILS.
To reset the oil monitoring system to 100% after each oil change [approximately 8000 km (5000
miles) or 180 days] perform the following:
1. Press the SETUP control to access the System Check function.
2. Press and release the RESET control to display "OIL LIFE XX% HOLD RESET NEW".
3. Press and hold the RESET control for 2 seconds to display "IF NEW OIL HOLD RESET".
4. Press and hold the RESET control to display "OIL LIFE SET TO 100%". Your oil life is now
reset.
To reset the oil monitoring system to your personalized oil life:
1. Press the SETUP control to access the System Check function.
2. Press and release the RESET control to display "OIL LIFE XX% HOLD RESET NEW".
3. Press and hold the RESET control for 2 seconds to display "IF
NEW OIL HOLD RESET".
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair > Page 10016
4. Release the RESET control momentarily, then press RESET and SETUP controls at the same
time to activate a service mode which will display
"OIL LIFE XX% RESET TO ALTER".
5. Press RESET until you find your personalized OIL LIFE XX%. 6. With your personalized OIL
LIFE XX% displayed, press SETUP to continue the system check.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
View 151-35
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 10020
View 151-53
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 10021
View 151-59
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Diagrams
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
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Component Information > Locations > Page 10029
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component
Information > Description and Operation
Seat Belt Reminder Buzzer: Description and Operation
Safety Belt Warning Indicator and Chime
The warning indicator and chime are reminders to fasten the safety belt. The system operates as
follows: If the driver safety belt is not buckled in the first six seconds after the ignition switch is turned to the
RUN or START position, the indicator will illuminate and the chime will toggle from on to off for six
seconds, for one minute.
- If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the
indicator and chime will turn off.
- If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides an additional reminder to the driver that the driver's safety belt is unbuckled by
intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument
cluster.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Description and Operation
Seat Belt Reminder Lamp: Description and Operation
Safety Belt Warning Indicator and Chime
The warning indicator and chime are reminders to fasten the safety belt. The system operates as
follows: If the driver safety belt is not buckled in the first six seconds after the ignition switch is turned to the
RUN or START position, the indicator will illuminate and the chime will toggle from on to off for six
seconds, for one minute.
- If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the
indicator and chime will turn off.
- If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides an additional reminder to the driver that the driver's safety belt is unbuckled by
intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument
cluster.
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Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10042
Door Switch: Locations Door Ajar Switch
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Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10044
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Door Switch > Component Information > Locations > Liftgate Ajar Switch > Page 10045
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Door Switch > Component Information > Diagrams > Liftgate Ajar Switch
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Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10048
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10049
Door Switch: Diagrams Door Ajar Switch
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Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10050
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: >
06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: >
06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10059
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: >
06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10061
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10062
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
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Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: >
06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10063
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: >
06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10064
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge
Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
Technical Service Bulletin # 06-2-12 Date: 060206
Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's
TSB 06-2-12
02/06/06
MIL ON WITH PCM DTC P0463 AND/OR IC DTC B1201 - FUEL GAUGE DROPS TO EMPTY OR
SLOW TO UPDATE AFTER REFUELING
FORD: 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 05-21-3 to update the Service Procedure.
ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a
customer complaint of the fuel gauge being slow to read full after refueling, the malfunction
indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201,
and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly
sending incorrect data to the instrument cluster and/or powertrain control module (PCM).
ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge
operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge
strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has
several distinct modes of operation. The difference in the various modes is the speed at which the
fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After
reviewing the General Information, refer to the TSB Service Procedure.
GENERAL INFORMATION
Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire
Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from "E" to "F" can
be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is
in.
Fast Acquire Mode:
The 2-second "E" to "F" mode is referred to as Fast Acquire Mode. Fast Acquire Mode strategy
requires two (2) conditions to be met before the fuel gauge indications can be updated. First, at
least four (4) gallons of fuel must be added to the fuel tank. Second, the Instrument Cluster must
acquire a valid Key-ON fuel sender reading within 1 second of the key being put in the Run
position. The Key-ON sample reading is considered valid if the fuel sender reading is between 10
and 160 ohms. If both of these conditions are not met, the fuel gauge stays in Slosh mode. If the
Cluster does not go into Fast Acquire Mode after a refueling event, the system will stay in Slosh
Mode. This will result in a slow to Read Full event.
Slosh Mode:
The 55-minute "E" to "F" mode is referred to as Slosh Mode. In Slosh Mode, this is 55 accumulated
minutes of the key in the Run position. Unless the conditions are met to put the fuel gauge into one
of the other operating modes, the default is Slosh Mode. Example: If a customer operates their
vehicle 11 minutes per day, it will take 5 days to accumulate 55 minutes of run time. This means it
will take 5 days for the fuel gauge to go from "E" to "F".
NOTE
SLOSH MOD[ STRATEGY WAS REDUCED FROM 55 MINUTES TO 17 MINUTES FOR
VEHICLES BUILT AFTER 12/22/2004.
NOTE
IT IS IMPORTANT TO THOROUGHLY UNDERSTAND THE CUSTOMER CONDITION BEING
REPORTED.
It is important to determine if the customer has a fuel gauge that slowly gets to full or has a fuel
gauge that never gets to "F" (stuck) when the fuel tank is filled. If the fuel gauge slowly goes from
"E" to "F" (in 55 minutes of key in the Run position or less), the problem is most likely not in the
cluster. It is absolutely imperative that the appropriate pinpoint test(s), located in the Workshop
Manual or this TSB, be completed for this customer complaint to determine root cause of the
condition. Root causes may include but are not limited to: the Fuel Sender, Fuel Tank, Wiring, or
Instrument Cluster
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge
Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10070
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
Disclaimer
Initial Steps (All Vehicles)
1. Retrieve and record PCM and the instrument cluster (IC) DTCs, from continuous and on-demand
self tests.
2. If DTCs other than B1201 or P0463 are retrieved, follow normal Workshop Manual diagnostics,
DO NOT CONTINUE WITH THIS TSB.
3. If IC DTC B1201 and/or PCM DTC P0463 are retrieved, perform Procedure A for 2002-2005
Model Years and Procedure B for 2006 Model Years.
4. If No DTCs are retrieved, go to Procedure C.
Procedure A
PROCEDURE A (2002-2005 MY)
CHECKING FUEL GAUGE OPERATION:
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY ON AND KEY OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
1. Key in OFF position.
2. Remove Fuse F1.15 (15 amp) from the Battery Junction Box, wait 1 minute and reinstall fuse.
NOTE
THIS IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect the in-line connector to the fuel pump module (C438 for 4.6L) or (C431 for 4.0L),
located on the RH frame rail.
4. On the vehicle harness side of the connector, connect one lead of an instrument gauge system
tester (Rotunda # 014-R1063 or equivalent) to Circuit 1356 (LG/VT - Pin-8 in Connector C438 and
C431) and the other lead to Circuit 1357 (LB/YE - Pin-5 in C438 for 4.6L or Pin-4 in C431 for 4.0L)
(Figure 1).
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
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Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10071
c. Turn key to the OFF position.
d. Set the tester to 160 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 15 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 160 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure B
PROCEDURE B (2006 MY)
NOTE
WHEN PERFORMING STEPS 4A-0, FUEL GAUGE SLOSH STRATEGY REQUIRES SPECIFIC
KEY-ON AND KEY-OFF CYCLE TIMES. THESE TIMES MUST BE OBSERVED OR THE
DIAGNOSTIC RESULTS WILL NOT BE ACCURATE.
CHECKING FUEL GAUGE OPERATION:
1. Key in OFF position.
2. Remove Fuse F24 (10 amp) from the Smart Junction Box, wait 1 minute and reinstall fuse.
NOTE
STEP 2 IS DONE TO RESET THE CLUSTER FUEL GAUGE TIMERS. FAILURE TO COMPLETE
THIS STEP MAY RESULT IN ERRONEOUS TEST RESULTS.
3. Disconnect: Fuel Pump Gauge Sender C433.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge
Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10072
4. Connect one lead of the instrument gauge system tester to the Fuel Pump Gauge Sender
C433-8, Circuit VMC11 (YE/VT), harness side and the other lead to the Fuel Pump Gauge Sender
C433-5, Circuit RMC32 (GN/BU), harness side. (Figure 2)
a. With the key in the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds
and then back to PARK.
b. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
c. Turn key to the OFF position.
d. Set the tester to 180 ohms.
e. Turn key to the RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and
then move the shift lever back to PARK.
f. Wait 30 seconds with the key in the RUN position and the shift lever in PARK.
g. Turn key to OFF position and wait 30 seconds.
h. Set the tester to 10 ohms.
i. Turn key to RUN position, move the shift lever from PARK to DRIVE, wait 10 seconds and then
move the shift lever back to PARK.
j. Wait 30 seconds with the key in the RUN Position and the shift lever in PARK.
NOTE
THE FUEL GAUGE SHOULD READ "E" (EMPTY MARK) OR BELOW WHEN CARRYING OUT
THIS TEST STEP.
k. Turn key to OFF position and wait 30 seconds.
l. Set the tester to 180 ohms.
m. Turn key to ON position.
NOTE
THE FUEL GAUGE SHOULD READ "F" (FULL) OR ABOVE WHEN CARRYING OUT THIS TEST
STEP.
n. Wait 1 minute for the gauge to respond.
o. Turn key to OFF position. After completing Steps 4A-0, if the fuel gauge operates correctly
replace the fuel sender only (9A299). If not, refer to the Workshop Manual, Section 413-01 and
perform normal diagnostics.
Procedure C
PROCEDURE C (2002-2006 MY With No DTCs)
NOTE
TO BEGIN DIAGNOSTIC PROCEDURE, SUBJECT VEHICLE MUST HAVE BETWEEN 1/4 AND
3/4 TANK OF FUEL.
1. Engage the Instrument Cluster Self-Diagnostic Test Mode by pressing and holding the
appropriate buttons for 4 seconds:
^ 2002-2006 - Base Cluster - Trip Odo Reset button
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge
Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10073
^ 2002-2005 - Message Center Cluster - SETUP and RESET Message Center buttons
^ 2006 - Message Center Cluster - RESET (only) Message Center button
a. With the vehicle in park, turn the key to the run position key on/engine off (KOEO).
b. Release the button(s):
^ 2002-2005 - Base Clusters will display "tESt"
^ 2002-2005 - Message Center Clusters will display "TEST"
^ 2006 - Clusters will indicate "ENGINEERING TEST MODE"
NOTE
IF "ENGINEERING TEST MODE" IS NOT DISPLAYED, DEPRESS THE ODO RESET OR
MESSAGE CENTER RESET BUTTON 1 OR MORE TIMES UNTIL THIS MESSAGE IS
DISPLAYED.
2. Access Raw Fuel Level data also called the Unfiltered Value by pressing:
^ 2002-2005 - Base Clusters - Trip Odo reset button 15 - 20 times for - until the display shows a "F"
followed by a 3-digit value (000 to 254)
^ 2002-2005 - Message Center Clusters - Message Center Reset button 18 times until the display
shows "FUEL A/D" or "FUEL LEVEL A/D"
^ 2006 Clusters - Trip Odo reset button 14 times until the display shows "FUEL LEVEL XXX INST"
where XXX is a value between 000 and 254
3. Rock the vehicle front to back (not side to side) at a slow and steady rate while noting the value
on the display
NOTE
THE UNFILTERED VALUE SHOULD CHANGE SMOOTHLY ALONG WITH THE FUEL SLOSH.
a. If this unfiltered value exceeds 231 at any point during this test, there is an open circuit in the
sender and/or wiring. Refer to Diagnostic Procedure A for 2002-2005 Model Years and Diagnostic
Procedure B for 2006 Model Year.
b. If the Unfiltered value drops below 28 at any point during the test, there is a shorted circuit in the
sender and/or wiring. Repair as necessary.
c. If the Unfiltered value stays between 028 - 231 during the test, the concern is intermittent. Refer
to the appropriate shop manual and follow normal diagnostics.
Tips For Procedure C And Optional Diagnostics:
^ If F is increasing and FP isn't - go to Cluster Diagnostic Section of Shop Manual
^ If FP and F are increasing and fuel level isn't - go to Cluster Diagnostic Section of Workshop
Manual
^ If Last line (Open) values aren't 255 and 254 (MY 05 and before), or 255 (MY 06) - go to Cluster
Diagnostic Section of Workshop Manual
^ If Open, or if F does not represent the level of fuel as described - then go to the Workshop
Manual and look for wiring and fuel sender issues. The cluster is not at fault
Optional Diagnostics
NOTE
THE FILTERED VALUE CAN ALSO BE DISPLAYED TO AID IN DIAGNOSIS. THE FILTERED
VALUE DIRECTLY RELATES TO THE POSITION OF THE FUEL GAGE POINTER.
^ 2005 - Message Center Clusters will indicate "PER XXX" on the second line of the Message
Center
^ 2003-2004 & 2006 - Clusters, the Trip Reset or Message Center Reset Button must be depressed
one additional time to display "FUEL LVL % XXX", "PER XXX", "FUEL STAT XXX %" or "FP XXX".
(XXX is a 3-digit value that ranges from 0 to 254) this is the filtered value. Wait 90 seconds and note
the position of the fuel gauge pointer, and the value on the Cluster Display. (Refer to the
appropriate Figure below)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge
Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10074
2002-2005 Units Built After 3/4/2002 - Non Flex Fuel Engine Equipped Vehicles (Figure 3)
2002-2005 Units Built After 3/4/2002 - 4.0L Flex Fuel Engine Equipped Vehicles (Figure 4)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge
Sender: > 06-2-12 > Feb > 06 > Instruments - Fuel Gauge Drops to Empty/MIL ON/DTC's > Page 10075
2006 Model Year Vehicles - All Engine Applications (Figure 5)
NOTE
VALUE IN REFERENCE CHARTS ARE NOMINAL TEST VALUES. (EX. A FULL FUEL TANK FILL
SHOULD INDICATE FULL, AND THE DISPLAY SHOULD INDICATE A VALUE BETWEEN 242
AND 254)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations
View 151-38
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations > Page 10079
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions
Low Tire Pressure Indicator: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10085
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10086
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10087
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10088
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10089
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10090
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10091
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10092
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10093
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10094
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10095
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10096
Low Tire Pressure Indicator: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10097
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10098
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10099
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10100
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10101
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10102
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10103
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10104
Low Tire Pressure Indicator: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
118-1
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Module > Component Information > Locations
View 151-4
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Module > Component Information > Locations > Page 10108
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Module > Component Information > Locations > Page 10109
Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System Module
1. Remove the components in the order indicated A0054813 in the following illustration and table.
Item Part Number Description 2. To install, reverse the removal procedure. 3. Train the tire
pressure sensors. 4. Reconfigure the module.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Specifications
Tire Pressure Sensor: Specifications
Tire pressure monitoring sensor valve stem nut
..................................................................................................................................... 7 Nm (62 inch
lbs.)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Specifications > Page 10113
Tire Pressure Sensor: Testing and Inspection
Sensor Training
NOTE: The tire pressure sensor training procedure must be done in an area without Radio
Frequency (RF) noise.
RF noise is generated by electrical motor and appliance operation, cellular telephones, and remote
transmitters.
1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch to the RUN position three
times, ending in the RUN position. Do not wait more than two minutes between each key cycle. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position three times, ending in the
RUN position. Do not wait more than two minutes
between each key cycle.
6. The horn will sound once and the TPMS indicator will flash if train mode has been entered
successfully. If equipped, the message center displays
"TRAIN LEFT FRONT TIRE". Place the magnet on the valve stem of the LF tire pressure sensor.
The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the
TPMS module.
7. Within two minutes after the horn sounds, place the magnet on the valve stem of the RF tire
pressure sensor.
NOTE: If the TPMS module does not recognize any one of the four tire pressure sensors during the
tire training procedure, the horn will sound twice and the message center (if equipped) will displays
"TIRE TRAINING MODE INCOMPLETE". If this occurs, the entire procedure must be repeated
from Step 1.
8. Repeat Step 7 for the RR and LR tires.
When the tire training procedure is complete, the horn will sound once and the message center (if
equipped) will displays "TIRE TRAINING MODE COMPLETE"
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Specifications > Page 10114
Tire Pressure Sensor: Service and Repair
Tire Pressure Sensor
CAUTION: Make sure to install a new sensor grommet or an air leak can occur.
NOTE: Do not remove the valve stem core to relieve the tire pressure.
1. Remove the wheel and tire assembly. 2. Remove the components in the order indicated in the
following illustration and table.
3. To install, reverse the removal procedure. 4. Train the tire pressure sensors. 5. Inflate the tire to
the pressure specified on the safety certification sticker located on the driver door jamb.
Item 2: Sensor Retainer Nut Removal Note
1. CAUTION: If the valve stem core has been removed from the valve stem, a new nickel-plated
core must be installed. Failure to use a
nickel-plated core will result in corrosion and the possible loss of tire pressure.
NOTE: Release the tire pressure by removing the sensor retaining nut.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Specifications > Page 10115
With the valve stem at the 6 o'clock position, remove the sensor retaining nut and allow the sensor
to fall into the tire.
Item 3: Tire Removal Note
1. CAUTION: Make sure that the valve stem mounting hole remains in the 6 o'clock position while
separating the beads of the tire.
Using a suitable tire machine, separate both beads of the tire from the wheel.
2. Place the wheel and tire on the turntable of the tire machine so that the valve stem hole is
positioned 270 degrees from the mounting/dismounting
fixture. Index-mark the valve stem and wheel weight positions.
- Lubricate the bead of the tire.
- Dismount the outside bead of the tire from the rim.
Item 3: Tire Installation Note
1. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire.
Lubricate and mount the outside bead of the tire in the rim.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair
Ambient Light Sensor: Service and Repair
PHOTOCELL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 10124
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations >
Brake Pedal Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations >
Brake Pedal Relay > Page 10130
Brake Lamp Relay: Locations Stoplamp Isolation Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations >
Brake Pedal Relay > Page 10131
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams >
Brake Pedal Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams >
Brake Pedal Relay > Page 10134
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Testing and
Inspection > Brake Pedal Relay
Brake Lamp Relay: Testing and Inspection Brake Pedal Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Testing and
Inspection > Brake Pedal Relay > Page 10137
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Testing and
Inspection > Brake Pedal Relay > Page 10138
Brake Lamp Relay: Testing and Inspection Stoplamp Isolation Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Testing and
Inspection > Brake Pedal Relay > Page 10139
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
View 151-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10143
View 151-26
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10144
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10145
Brake Light Switch: Service and Repair
BRAKE PEDAL POSITION (BPP) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 10157
(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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 10163
(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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > Page 10164
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Diagrams > Page 10169
Courtesy Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Diagrams > Page 10170
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations
View 151-56
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations > Page 10178
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Locations > Page 10179
Daytime Running Lamp Control Unit: Service and Repair
DAYTIME RUNNING LAMP (DRL) MODULE
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Page 10183
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Page 10184
Daytime Running Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Information > Locations > Page 10185
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 10189
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 10190
Battery Discharge Protection Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 10191
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch
View 151-43
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10196
View 151-42
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10197
Door Switch: Locations Door Ajar Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10198
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10199
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Ajar Switch >
Page 10200
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch >
Page 10203
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch >
Page 10204
Door Switch: Diagrams Door Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch >
Page 10205
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10210
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10211
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10212
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 10217
Hazard Warning Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 10218
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 10219
Hazard Warning Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations > Page 10220
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10225
Headlamp Dimmer Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10226
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10227
Headlamp Dimmer Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 10228
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Main Light Switch
View 151-27
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Main Light Switch > Page 10233
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Multifunction Switch
Headlamp Switch: Diagrams Multifunction Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Multifunction Switch > Page 10236
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Multifunction Switch > Page 10237
Headlamp Switch: Diagrams Main Light Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Exterior Lamps
Headlamp Switch: Testing and Inspection Exterior Lamps
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Exterior Lamps > Page 10240
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Exterior Lamps > Page 10241
Headlamp Switch: Testing and Inspection Interior Lamps
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Exterior Lamps > Page 10242
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and
Inspection > Page 10243
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
REMOVAL
1. Remove the instrument cluster finish panel.
2. Remove the headlamp switch from the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations >
Page 10247
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations >
Page 10248
High Beam Relay: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations >
Page 10249
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10254
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10255
Horn Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10256
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10264
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10265
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10266
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10267
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10268
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10269
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10270
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10271
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10272
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10273
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10274
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10275
License Plate Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10276
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10277
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10278
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10279
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10280
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10281
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10282
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10283
License Plate Lamp: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10284
License Plate Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10285
92-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10286
92-3
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10291
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10292
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10293
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10294
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10295
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10296
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10297
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10298
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10299
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10300
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10301
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10302
Marker Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10303
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10304
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10305
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10306
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10307
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10308
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10309
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10310
Marker Lamp: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10311
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10312
Marker Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10313
92-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10314
92-3
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 10315
Marker Lamp: Service and Repair
SIDE LAMP ASSEMBLY
NOTE: RH shown, LH similar.
REMOVAL
1. Remove the front fender splash shield.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Parking Lamp: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10320
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10321
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10322
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10323
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10324
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10325
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10326
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10327
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10328
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10329
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10330
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10331
Parking Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10332
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10333
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10334
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10335
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10336
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10337
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10338
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10339
Parking Lamp: Connector Views
C1023
C1115
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10340
C4032
C4034
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10341
C4035
C4036
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10342
C1043
C1116
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10343
Parking Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10344
92-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10345
92-3
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Parking Lamp: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step.
NOTE: Make sure the headlamp switch is in the OFF position.
4. If the cause is not visually evident, connect the diagnostic tool to the data link connector and
select the vehicle to be tested from the diagnostic tool
menu. If the diagnostic 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 position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
- SCP+, SCP- or UBP circuit fault; all electronic control units no response/not equipped, refer to
Module Communications Network (Information Bus).
- No response/not equipped for the vehicle security module, refer to Module Communications
Network (Information Bus).
- System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the
continuous DTCs and carry out the self-test diagnostics for the vehicle security module.
7. If the DTCs retrieved are related to the concern, refer to the Vehicle Security Module Diagnostic
Trouble Code (DTC) Index to continue
diagnostics. See: Diagnostic Trouble Code Descriptions
8. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
NOTE: For a complete master list of DTCs, refer to Module Communications Network (Information
Bus).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10348
DTC Index B2661 - B2662
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10349
Symptom Chart
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10350
Parking Lamp: Pinpoint Tests
Explorer: LH Parking/Turn Lamp C1023, RH Park/turn Lamp C1043
Headlamp Switch C205a
LH License Lamp C452, RH License Lamp C462
LH Rear Lamp C4032 and C4035, RH Rear Lamp C4034 and C4036
LH REAR LAMP C4032 AND C4035 (EXPLORER), RH REAR LAMP C4034 AND C4036
(MOUNTAINEER)
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10351
LH Rear Lamp C4032 And C4035 (Explorer), RH Rear Lamp C4034 And C4036 (Mountaineer)
LH Side C481, RH Side C482, RH Side C1126, LH Side C1127
LH SIDE MARKER C481, RH SIDE MARKER C482, RH SIDE MARKER C1126, LH SIDE
MARKER C1127
LH Side Marker C481, RH Side Marker C482, RH Side Marker C1126, LH Side Marker C1127
LH Tail Lamp C412, RH Tail Lamp C415
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10352
Vehicle Security Module C3008e
Test O
PINPOINT TEST O: THE EXTERIOR LAMPS ARE INOPERATIVE
Test O1-O2
Normal Operation
With the headlamp switch turned to the autolamp position, a battery voltage signal is sent to the
vehicle security module through circuit 1399 (DB/WH). The vehicle security module then
determines the amount of ambient light based on the input received from the photocell. The input
signal is received through circuit 218 (WH/VT). When the ambient level has reached a point
(determined by the internal programming of the vehicle security module), two internal relays are
energized to supply power to the exterior lamps. Circuit 195 (TN/WH) supplies power to the internal
parking lamp relay, which in turn supplies power to circuit 14 (BN) when energized. Circuit 1205
(BK) is the ground circuit for the photocell. When the headlamp switch is turned to the headlamp or
parklamp position, voltage is supplied directly to circuit 14 (BN). Current then flows directly to all
the exterior lights. Ground is provided to the bulbs through circuit 1205 (BK).
Possible Causes
- circuit 14 (BN) open
- circuit 195 (TN/WH) open
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10353
- circuit 1205 (BK) open
- vehicle security module
- headlamp switch
Test P
PINPOINT TEST P: THE AUTOLAMPS OPERATE, BUT PARKING, REAR OR LICENSE LAMPS
ARE INOPERATIVE
Test P1-P2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10354
Test P3-P4
Normal Operation
The headlamp switch is supplied battery voltage through circuit 195 (TN/WH). When the headlamp
switch is turned to the parking lamps ON position, the headlamp switch supplies voltage to circuit
14 (BN), which in turn supplies power to the exterior lamps. Ground is provided to the bulbs
through circuit 1205 (BK).
Possible Causes
- circuit 14 (BN) open
- circuit 195 (TN/WH) open
- vehicle security module
Test Q
PINPOINT TEST Q: ONE OR MORE PARKING, REAR OR LICENSE LAMPS IS INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10355
Test Q1
Normal Operation
The headlamp switch is supplied battery voltage through circuit 195 (TN/WH). When the headlamp
switch is turned to the parking lamps ON position, the headlamp switch supplies voltage to circuit
14 (BN), which in turn supplies power to the exterior lamps. Ground is provided to the bulbs
through circuit 1205 (BK).
Possible Causes
- circuit 14 (BN) short to power
- circuit 109 (VT/WH) open
- circuit 1205 (BK) open
Test R
PINPOINT TEST R: THE PARKING, REAR OR LICENSE LAMPS ARE ON CONTINUOUSLY
Test R1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10356
Test R2-R4
Normal Operation
The headlamp switch is supplied battery voltage through circuit 195 (TN/WH). When the headlamp
switch is turned to the parking lamps ON position, the headlamp switch supplies voltage to circuit
14 (BN), which in turn supplies power to the exterior lamps. Ground is provided to the bulbs
through circuit 1205 (BK).
Possible Causes
- circuit 14 (BN) short to power
- headlamp switch
- vehicle security module
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Page
10357
73III Automotive Meter
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 10362
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 10363
Battery Discharge Protection Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 10364
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Locations > Brake Pedal Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Locations > Brake Pedal Relay > Page 10369
Brake Lamp Relay: Locations Stoplamp Isolation Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Locations > Brake Pedal Relay > Page 10370
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Diagrams > Brake Pedal Relay
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Diagrams > Brake Pedal Relay > Page 10373
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay
Brake Lamp Relay: Testing and Inspection Brake Pedal Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay > Page 10376
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay > Page 10377
Brake Lamp Relay: Testing and Inspection Stoplamp Isolation Relay
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay >
Component Information > Testing and Inspection > Brake Pedal Relay > Page 10378
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 10382
Courtesy Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Diagrams > Page 10383
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations
View 151-56
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 10387
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Locations > Page 10388
Daytime Running Lamp Control Unit: Service and Repair
DAYTIME RUNNING LAMP (DRL) MODULE
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Page 10392
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Page 10393
Daytime Running Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Locations > Page 10394
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10398
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10399
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10400
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 10404
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 10405
High Beam Relay: Testing and Inspection
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Locations > Page 10406
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 10410
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 10411
Horn Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 10412
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 10420
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 10421
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 10424
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 10425
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 10426
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Diagrams > Trailer Tow Relay, Right Turn > Page 10427
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10430
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10431
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10432
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10433
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10434
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10435
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10436
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10437
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Testing and Inspection > Trailer Tow Relay, Right Turn > Page 10438
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 10442
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 10443
Turn Signal Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Locations > Page 10444
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Service and Repair
Ambient Light Sensor: Service and Repair
PHOTOCELL
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
View 151-6
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 10452
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
View 151-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10456
View 151-26
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10457
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10458
Brake Light Switch: Service and Repair
BRAKE PEDAL POSITION (BPP) SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch
View 151-43
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10463
View 151-42
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10464
Door Switch: Locations Door Ajar Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10465
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10466
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Ajar Switch > Page 10467
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 10470
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 10471
Door Switch: Diagrams Door Ajar Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Ajar Switch > Page 10472
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations > Page 10476
Hazard Warning Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations > Page 10477
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations > Page 10478
Hazard Warning Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations > Page 10479
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10483
Headlamp Dimmer Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10484
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10485
Headlamp Dimmer Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10486
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Main Light Switch
View 151-27
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Main Light Switch > Page 10491
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Multifunction Switch
Headlamp Switch: Diagrams Multifunction Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Multifunction Switch > Page 10494
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Multifunction Switch > Page 10495
Headlamp Switch: Diagrams Main Light Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Exterior Lamps
Headlamp Switch: Testing and Inspection Exterior Lamps
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Exterior Lamps > Page 10498
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Exterior Lamps > Page 10499
Headlamp Switch: Testing and Inspection Interior Lamps
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Exterior Lamps > Page 10500
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Testing and Inspection > Page 10501
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
REMOVAL
1. Remove the instrument cluster finish panel.
2. Remove the headlamp switch from the instrument cluster finish panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10505
Turn Signal Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10506
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10507
Turn Signal Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10508
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10513
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10514
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10515
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10516
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10517
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10518
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10519
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10520
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10521
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10522
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10523
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10524
Tail Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10525
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10526
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10527
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10528
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10529
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10530
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10531
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10532
Tail Lamp: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10533
Tail Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10534
92-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10535
92-3
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions
Trailer Lamps: Diagram Information and Instructions
How To Find Wiring Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
Circuits feeding/protecting the system diagrams
^ System Diagrams
Component Circuits that work together as a system
^ Grounds Diagrams
Circuits grounding the system diagrams
Power Distribution Diagrams
The power distribution diagrams are located at Power and Ground Distribution.
These diagrams are especially useful for identifying potential suspects that could be causing any
"dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any
"blown" fuses.
System Diagrams
These diagrams are useful for identifying a component's power source and its direct relationship to
the other components in the same system. These diagrams may also indicate a component's
indirect relationship with components in other systems.
Grounds Diagrams
The grounds diagrams are located at Power and Ground Distribution.
These diagrams are useful for determining the interconnections of the grounding circuits of different
systems.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
How To Navigate Between Wiring Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10540
Circuits that go from one diagram to another will be marked with references indicating which
diagram the circuit went to/came from, i.e. "See Diagram ##-#".
These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc).
All diagrams are identified with this unique ID number in their captions.
Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be
accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of
diagrams.
PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be
missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do
not apply to the vehicle model selected.
Introduction To Ford Diagrams
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagram to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set of diagrams. Other components
which are connected to the circuit may not be shown unless they influence the circuit operation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10541
System Overview
Each major vehicle system includes a complete system overview diagram prior to each set of
diagrams. It is important to realize that this is only a high level overview of the complete system
connectivity. It includes component operational information (1), component name and base part
number (2), and basic component internals (3). It does not include specific circuit information,
connector or pin numbers, splices or grounds. That information is found on the subsequent
diagrams in the set.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10542
Current Flow (1)
Each set of diagrams normally starts with the component that powers the circuit such as a fuse or
the ignition switch. Current flow is shown from the power source at the top of the diagram to ground
at the bottom of the diagram. In order to concentrate on the essential parts, power supply and
ground connections are sometimes simplified by a dashed line in the diagrams. A full
representation of the power supply of a fuse or the power distribution from a fuse to various
components is given in the Power and Ground Distribution Diagrams. Full representation of the
ground connections are shown in the Power and Ground Distribution Diagrams.
Switch Positions (2)
Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch
were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the diagram
where the splice appears in full.
Component Referencing (4)
Each component on a diagram has a reference to the component location view for that component
(i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown
in a diagram. The views themselves can be found at Vehicle Locations.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the right hand side of each component. Any notes that describe
switch positions or operating conditions follow the name. Descriptions of the internals of the
component are also included here. The base part number for a component is listed in parentheses
next to or under a component.
Internal Name and Function ID Numbers (6)
Some components on each diagram have internal symbols with an identification number located to
the right. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10543
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and
relays are identified.
Power Distribution
Power and Ground Distribution Diagrams show the current feed circuit. The current path is shown
from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each
fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors)
between the fuse and the first component are shown.
Ground Distribution
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10544
Power and Ground Distribution Diagrams contain the diagrams that show the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the components are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
Component and Connector Information
Locations information that can be found at the vehicle level will help the user find where the various
items depicted on the diagram can physically be found on the vehicle.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
"Connector Views" show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector.
WARNINGS
^ Always wear safety glasses for eye protection.
^ Use safety stands whenever a procedure requires being under a vehicle.
^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the
procedure.
^ Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
^ Keep away from moving parts, especially the fan and belts, when the engine is running.
^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tailpipe, catalytic converter and muffler.
^ Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
^ Do not smoke when working on a vehicle.
^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Location Key For Connectors, Grounds, and Splices
The first digit of every connector, ground, and splice references its location within the vehicle.
NUMBER .............................................................................................................................................
........................................................... LOCATION
100 .................................................................................................................. Engine compartment,
Powertrain (including: axle/differential/transmission) 200
................................................................................................................................................
Instrument Panel and Console, Steering Wheel assembly 300
.............................................................................................................................................. From
instrument panel to rear seat, below door trim panel 400 ...................................................................
............................................................................................... Behind rear seats, to rear bumper;
Truck bed 500 ......................................................................................................................................
................................................................................. Driver door 600 ..................................................
......................................................................................................................................................
Passenger door, front 700 ...................................................................................................................
................................................................................ Passenger door, left rear 800 .............................
..............................................................................................................................................................
...... Passenger door, right rear
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10545
900 .......................................................................................................................................................
........................ Above door trim panel and headliner
Symbols and Wire Color Code Identification
Symbols Part 1
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10546
Symbols Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10547
Symbols Part 3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10548
Symbols Part 4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10549
Symbols Part 5
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10550
Systems Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10551
Trailer Lamps: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation in each illustration.
NOTE: Several components, such as the Powertrain Control Module (PCM), utilize gold plated
terminals in their connections to the wiring harness. If those terminals need to be replaced, they
must be replaced with a gold plated terminal.
Terminal not properly seated
1 Locked terminal
2 Male half
3 Female half
4 Seal
5 Intermittent contact
6 Unlocked terminal (Hidden by wire seal)
7 Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10552
Defective insulation stripping
1 Proper crimp
2 Insulation not removed
3 Wire strands missing
4 Intermittent signals through pierced insulation
Partially mated connectors
1 Seal
2 Displaced tab
3 Female half
4 Seal
5 Intermittent contact
6 Male half
7 Intermittent contact
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10553
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 Enlarged
2 Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 Solder coated wire to ground
2 Harness protective tape
3 Intermittent short Solder coated wire pierced through the insulation of another circuit
4 Grounding foil
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10554
Electrical short within the harness
Splice tape removed 1
Intermittent short
Splice covered 1
Wire strand
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10555
2 Splice tape
3 Harness tape
Broken wire strands in harness
1 Wiring harness tape
2 Wiring strand
3 Broken strands intermittent signal
4 Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10556
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use Rosin Core Mildly-Activated (RMA) solder. Do not use acid core solder.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10557
6. Bend Wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10558
8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink
tubing. 9. Reconnect battery ground cable.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10559
Trailer Lamps: Electrical Diagrams
Trailer/Camper Adapter
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1, System Overview
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10560
95-2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10561
95-3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10562
95-4
Diagrams -- Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations -- Location views (reference numbers starting with 151-) referred to within these
diagrams can be found at Component Location Views. See: Diagrams/Components/Component
Location Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating
correctly. If not, refer to the appropriate pinpoint test. See: Pinpoint Tests 3. Visually inspect for
obvious signs of mechanical or electrical damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuse(s): 13 (40A)
- 20 (30A)
- 27 (20A)
- Central junction box (CJB) fuse 25 (5A)
- Circuitry
- Relay(s)
- Bulb(s)
NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are
all functioning correctly with the trailer disconnected.
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 5. If the concern is not visually evident, verify the symptom and
GO to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10565
Symptom Chart
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10566
Trailer Lamps: Pinpoint Tests
Trailer Tow Battery Charge Relay C4021, C4022
TRAILER TOW BATTERY CHARGE RELAY C4021, TRAILER TOW PARKING LAMP RELAY
C4022
Trailer Tow Battery Charge Relay C4021, Trailer Tow Parking Lamp Relay C4022
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10567
Trailer Tow C439 (4-pin Connector)
Trailer Tow C473 (7-pin Connector), Part 1
Trailer Tow C473 (7-pin Connector), Part 2
Trailer Tow C1187, C1188, C4023
TRAILER TOW RH TURN RELAY C1187, TRAILER LOW LH TURN RELAY C1188, TRAILER
TOW REVERSING LAMP RELAY C4023
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10568
Trailer Tow RH Turn Relay C1187, Trailer Tow LH Turn Relay C1188, Trailer Tow Reversing Lamp
Relay C4023, Part 1
Trailer Tow RH Turn Relay C1187, Trailer Tow LH Turn Relay C1188, Trailer Tow Reversing Lamp
Relay C4023, Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10569
Trailer Tow Electronic Brake Control Module C239
Test Y
PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE
Test Y1
Normal Operation
Circuit 14 (BN) supplies power to the exterior lamps and the coil side of the trailer tow parking lamp
relay. When the trailer tow parking lamp relay is energized, voltage received from circuit 1043
(DG/YE) is switched to the trailer tow connector through circuit 962 (BN/WH). Ground is supplied to
the trailer tow parking lamp relay through circuit 1205 (BK).
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10570
Possible Causes
- trailer
Test Z
PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - RH TRAILER TURN
SIGNALS/STOPLAMPS/HAZARD LAMPS
Test Z1-Z3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10571
Test Z4-Z5
Normal Operation
When the RH trailer tow turn relay is energized, power is routed from circuit 175 (BK/YE) to the
trailer tow connector through circuit 64 (DG). When circuit 378 (BN/YE) is supplied power from the
multifunction switch (such as when the brakes are applied or the RH turn signal is engaged), the
RH turn relay is energized. Ground is supplied to the trailer tow turn lamp relays through circuit
1205 (BK).
Possible Causes
- circuit 64 (DG) open
- circuit 175 (BK/YE) open
- circuit 378 (BN/YE) open
- circuit 1205 (BK) open
- trailer tow turn lamp relay
- trailer
Tests AA
PINPOINT TEST AA: THE TRAILER LAMPS ARE INOPERATIVE - LH TRAILER TURN
SIGNAL/STOPLAMP/HAZARD LAMPS
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10572
Test AA1-AA3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10573
Test AA4-AA5
Normal Operation
When the LH trailer tow turn relay is energized, power is routed from circuit 175 (BK/YE) to the
trailer tow connector through circuit 52 (YE). When circuit 374 (DB/WH) is supplied power from the
multifunction switch (such as when the brakes are applied or the LH turn signal is engaged), the LR
turn relay is energized.
Possible Causes
- circuit 52 (YE) open
- circuit 175 (BK/YE) open
- circuit 374 (DB/WH) open
- circuit 1205 (BK) open
- trailer tow turn lamp relay
- trailer
Tests AB
PINPOINT TEST AB: THE TRAILER LAMPS ON INOPERATIVE - PARKING LAMPS
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10574
Test AB1-AB3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10575
Test AB4-AB5
Normal Operation
Circuit 14 (BN), under normal operation, supplies power to the exterior lamps and the coil side of
the trailer tow parking lamp relay. When the trailer tow parking lamp relay is energized, voltage
received from circuit 1043 (DG/YE) is switched to the trailer tow connector through circuit 962
(BN/WH). Ground is supplied to the trailer tow parking lamp relay through circuit 1205 (BK).
Possible Causes
- circuit 14 (BN) open
- circuit 962 (BN/WH) open
- circuit 1043 (DG/YE) open
- circuit 1205 (BK) open
- trailer tow parking lamp relay
- trailer
Tests AC
PINPOINT TEST AC: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10576
Test AC1-AC3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10577
Test AC4-AC5
Normal Operation
Circuit 140 (BK/PK) supplies power to the reversing lamps and the coil side of the trailer tow
reversing lamp relay. When the trailer tow reversing lamp relay is energized, voltage received from
circuit 1043 (DG/YE) is switched to the trailer tow connector through circuit 963 (BK/LG). Ground is
supplied to the trailer tow reversing lamp relay through circuit 1205 (BK).
Possible Causes
- circuit 140 (BK/PK) open
- circuit 963 (BK/LG) open
- circuit 1043 (DG/YE) open
- circuit 1205 (BK) open
- trailer tow reversing lamp relay
- trailer
Tests AD
PINPOINT TEST AD: THE TRAILER LAMPS ARE ON CONTINUOUSLY
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10578
Test AD1-AD4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10579
Test AD5-AD7
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10580
Test AD7 Continued
Normal Operation
Circuit 14 (BN) supplies power to the exterior lamps and the coil side of the trailer tow parking lamp
relay. When the trailer tow parking lamp relay is energized, voltage received from circuit 1043
(DG/YE) is switched to the trailer tow connector through circuit 962 (BN/WH). Circuit 140 (BK/PK)
supplies power to the reversing lamps and the coil side of the trailer tow reversing lamp relay.
When the trailer tow reversing lamp relay is energized, voltage received from circuit 1043 (DG/YE)
is switched to the trailer tow connector through circuit 963 (BK/LG).
Possible Causes
- circuit 52 (YE) short to power
- circuit 64 (DG) short to power
- circuit 962 (BN/WH) short to power
- circuit 963 (BK/LG) short to power
- trailer tow reversing lamp relay
- trailer tow parking lamp relay
- trailer tow RH turn or LH turn relay
- trailer
Tests AE
PINPOINT TEST AE: THE TRAILER BATTERY CHARGING IS INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10581
Test AE1-AE3
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10582
Test AE4-AE5
Normal Operation
The trailer battery charging is accomplished through the use of the trailer tow battery charge relay.
Power is supplied to the trailer tow battery charge relay by circuit 175 (BK/YE) and when
energized, provides power to the trailer tow connector through circuit 49 (OG). The control circuit
for the trailer tow battery charge relay is provided by circuit 1003 (GY/YE) Ground is provided to the
trailer tow battery charge relay through circuit 1205 (BK).
Possible Causes
- circuit 49 (OG) open
- circuit 175 (BK/YE) open
- circuit 1003 (GY/YE) open
- circuit 1205 (BK) open
- trailer tow battery charge relay
- trailer
Tests AF
PINPOINT TEST AF: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10583
Test AF1-AF2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10584
Test AF3-AF4
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10585
Test AF5
Normal Operation
The trailer tow electronic brake control module receives power through circuit 1051 (PK/WH) and
provides output power to the trailer tow connector through circuit 43 (DB). The trailer tow electronic
brake control module is grounded through circuit 1205 (BK). The trailer tow electronic brake control
module also receives input when the parking lamps are illuminated through circuit 14 (BN) and the
BPP switch through circuit 511 (LG) when the brake pedal is applied.
Possible Causes
- circuit 14 (BN) open
- circuit 43 (DB) open, shorted to power or shorted to ground
- circuit 511 (LG) open
- circuit 1051 (PK/WH) open
- circuit 1205 (BK) open
- trailer tow electronic brake control module
- trailer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page
10586
73III Automotive Meter
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow
Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow
Relay, Battery Charge > Page 10591
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow
Relay, Battery Charge > Page 10592
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Right Turn
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Right Turn > Page 10595
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Right Turn > Page 10596
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Right Turn > Page 10597
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow
Relay, Right Turn > Page 10598
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10601
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10602
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10603
Relay - Micro ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10604
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Reversing Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10605
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10606
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10607
Relay - Mini ISO
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10608
Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection >
Trailer Tow Relay, Right Turn > Page 10609
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front
Turn Signal Lamp: Diagrams Park/Turn Lamp, Left Front
C1023
C1115
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10615
C1108
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10616
C1109
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10617
Turn Signal Lamp: Diagrams Park/Stop/Turn Lamp, Right Rear
C4032
C4034
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10618
Turn Signal Lamp: Diagrams
C1023
C1115
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10619
C1108
C1109
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10620
C4032
C4034
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10621
C1043
C1116
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp, Left Front > Page 10622
C4035
C4036
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Page 10623
Turn Signal Lamp: Service and Repair
SIDE TURN SIGNAL LAMP
NOTE: RH shown, LH similar.
REMOVAL
1. Remove the headlamp.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations >
Page 10627
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations >
Page 10628
Turn Signal Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations >
Page 10629
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
View 151-25
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10633
Turn Signal Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10634
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10635
Turn Signal Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10636
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left > Page 10641
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 10647
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 10648
Heated Glass Element Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 10649
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10654
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10655
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10656
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10657
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 10658
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 Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 10663
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 10664
Heated Glass Element Relay: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 10665
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch
Power Window Switch: Locations Window Adjust Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 10671
View 151-49
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Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 10672
View 151-50
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Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Window Adjust Switch > Page 10673
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 10676
Power Window Switch: Diagrams Window Adjust Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Master Window Adjust Switch > Page 10677
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10680
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10681
Power Window Switch: Testing and Inspection Power window Switch
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10682
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 10683
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Window Control Switch Bezel Removal Note
1. Lift the front of the window control switch bezel upward to release the front hold-down clip. 2.
Slide the window control switch bezel forward to release the rear tab.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Diagrams > Left Front
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Diagrams > Left Front > Page 10690
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct >
07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Motor: Customer Interest Body - Rear Door Window Stuck In Up
Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct >
07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10699
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: >
07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Motor: All Technical Service Bulletins Body - Rear Door Window Stuck In Up
Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: >
07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10705
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch
Power Window Switch: Locations Window Adjust Switch
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 10710
View 151-49
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 10711
View 151-50
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Window Adjust Switch > Page 10712
View 151-51
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch
Power Window Switch: Diagrams Master Window Adjust Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 10715
Power Window Switch: Diagrams Window Adjust Switch
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Master Window Adjust Switch > Page 10716
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 10719
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 10720
Power Window Switch: Testing and Inspection Power window Switch
Introduction To Component Testing
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 10721
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 10722
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
REMOVAL
1. Remove the components in the order indicated in the illustration and table.
Item 1: Window Control Switch Bezel Removal Note
1. Lift the front of the window control switch bezel upward to release the front hold-down clip. 2.
Slide the window control switch bezel forward to release the rear tab.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
DOOR WINDOW GLASS - FRONT
REMOVAL
1. Remove the front door speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair > Page 10727
Part 1
Part 2
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair > Page 10728
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 3: Front Door Window Glass-to-Regulator Bolts Removal Note
NOTE: Some vehicles may use rivets to attach the window.
1. Lower the front door window glass as necessary to access bolts.
2. If removing the front door regulator assembly and motor, secure the front door glass in the full up
position with tape.
Item 4: Front Door Window Glass Removal Note
1. Pull glass out through the top inboard side of the door.
Item 12: Glass Top Run Channel Assembly Removal Note
1. Remove the top glass run channel thorough the top opening of the front door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair
Liftgate Window Glass: Service and Repair
LIFTGATE WINDOW GLASS
REMOVAL
1. If installing a new liftgate window glass, remove the rear wiper motor.
2. Remove components in the order indicated in the illustration and table.
Item 1: Liftgate Trim Panel Removal Note
1. Position liftgate trim panel out of the way to access electrical connections and liftgate window
glass nuts.
Item 3: Liftgate Window Glass Struts Removal Note
1. CAUTION: Open and support the liftgate before removing the liftgate window glass struts.
Disconnect the liftgate window glass struts at the liftgate glass.
Item 5: Liftgate Window Glass Removal Note
1. CAUTION: Be sure not to scratch the applique located at the bottom of the glass.
With the help of an assistant, remove the liftgate window glass.
INSTALLATION
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair > Page 10732
1. NOTE: Transfer components as necessary.
To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair
Quarter Window Glass: Service and Repair
REAR QUARTER WINDOW GLASS
REMOVAL
1. Remove the rear quarter trim panel and rear coat hook.
2. Remove the components in the order indicated in the illustration and table.
INSTALLATION
1. To install, reverse the removal procedure.
Item 3: Buytl Installation Note
1. NOTE:
- When applying sealant, leave a slight gap at the bottom to allow for drainage.
- When applying sealant, start at the rear of the window glass frame and uniformly work sealant
around it.
Apply 6 mm (0.24 in) sealant or equivalent to the rear quarter window glass frame.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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
DOOR WINDOW GLASS - REAR
NOTE: RH side is shown. LH side is similar.
REMOVAL
1. Remove the rear door-mounted speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 10739
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 10740
2. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
Item 4: Rear Door Glass-To-Regulator Bolts Removal Note
NOTE: Some vehicles may use rivets to attach the glass to the regulator.
1. Lower the rear door window glass as necessary to access bolt.
2. If removing the rear door glass regulator assembly and motor, secure the rear door glass in the
full up position with tape.
3. If removing the rear door glass regulator assembly and motor, remove the inside door handle but
do not disconnect the latch cable.
1 Remove the screw.
2 Disengage the inside door handle from the door.
Item 5: Rear Door Window Glass Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 10741
1. Pull the glass out through the top inboard side of the door.
Item 12: Rear Door Window Glass Top Run Removal Note
1. Remove the glass top run through the top opening of rear door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair
Front Door Window Regulator: Service and Repair
WINDOW GLASS - FRONT DOOR
REMOVAL
1. Remove the front door speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10746
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10747
2. Remove the components in the order indicated in the illustration and table.
To remove individual components, only carry out the listed steps.
3. To install, reverse the removal procedure.
Item 2: Front Door Weatherstrip Removal Note.
1. Disconnect the lock rod at the handle assembly.
Item 3: Front Door Window Glass-to-Regulator Bolts Removal Note
CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet
removal process. If the holes become enlarged, the new rivets may become loose, resulting in a
clicking noise concern.
NOTE: Some vehicles may use rivets to attach the window.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
1. Lower the front door window glass as necessary to access bolts.
2. If removing the front door regulator assembly and motor, secure the front door glass in the full up
position with tape.
Item 4: Front Door Window Glass Removal Note
1. Pull glass out through the top inboard side of the door.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10748
Item 12: Glass Top Run Channel Assembly Removal Note
1. Remove the top glass run channel thorough the top opening of the front door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct > 07 >
Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Regulator: Customer Interest Body - Rear Door Window Stuck In Up
Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct > 07 >
Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10757
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 07-20-5 > Oct
> 07 > Body - Rear Door Window Stuck In Up Position/Inoperative
Rear Door Window Regulator: All Technical Service Bulletins Body - Rear Door Window Stuck In
Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 07-20-5 > Oct
> 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10763
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10764
Rear Door Window Regulator: By Symptom
Technical Service Bulletin # 07-20-5 Date: 071015
Body - Rear Door Window Stuck In Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10765
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10766
Disclaimer
Technical Service Bulletin # 07-20-5 Date: 071015
Body - Rear Door Window Stuck In Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10767
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10768
Disclaimer
Technical Service Bulletin # 07-20-5 Date: 071015
Body - Rear Door Window Stuck In Up Position/Inoperative
TSB 07-20-5
10/15/07
REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION
FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer
LINCOLN: 2003-2005 Aviator
MERCURY: 2002-2006 Mountaineer
This article supersedes TSB 07-16-14 to update the Part List.
ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and
2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks
in the up position. This condition can be intermittent and may be due to the power motor which
temporarily locks up.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel
and inspect the window regulator for damaged parts.
2. If any damage part or parts are found replace the regulator assembly.
3. If no damaged parts are found on the regulator assembly, replace the window regulator motor
using WSM, Section 501-11.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
072005A 2002-2005 Explorer Sport 0.9 Hr.
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9)
072005B 2002-2005 Explorer Sport 1.6 Hrs.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10769
Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install
Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9)
072005C 2002-2006 0.4 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel:
One Rear Door (Do
Not Use With 27406B, 27406B8, 27406B9)
072005D 2002-2006 0.7 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time
To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
072005E 2002-2006 0.6 Hr.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B,
27406B8, 27406B9)
07200SF 2002-2006 1.1 Hrs.
Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes
Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B,
27406B8, 27406B9)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7823394 07
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10770
Disclaimer
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > Page 10771
Rear Door Window Regulator: Service and Repair
WINDOW GLASS - REAR DOOR
NOTE: RH side is shown. LH side is similar.
REMOVAL
1. Remove the rear door-mounted speaker.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > Page 10772
Part 1
Part 2
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > Page 10773
2. Remove the components in the order indicated in the illustration and table.
To remove individual components, only carry out the listed steps.
3. To install, reverse the removal procedure.
Item 4: Rear Door Glass-To-Regulator Bolts Removal Note
CAUTION: Make sure the hole in the glass bracket do not become enlarged during the rivet
removal process. If the hole become enlarged, the new rivets may become loose, resulting in a
clicking noise concern.
NOTE: Some vehicles may use rivets to attach the glass to the regulator.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
1. Lower the rear door window glass as necessary to access the bolts or rivets.
2. If removing the rear door glass regulator assembly and motor, secure the rear door glass in the
full up position with tape.
3. If removing the rear door glass regulator assembly and motor, remove the inside door handle but
do not disconnect the latch cable.
1 Remove the screw.
2 Disengage the inside door handle from the door.
Item 5: Rear Door Window Glass Removal Note
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Technical Service Bulletins > Page 10774
1. Remove the applique on the rear door.
- Remove the screws.
2. Pull the glass out through the top inboard side of the door.
Item 10: Window Regulator Motor Removal Note.
1. Before removing the window regulator motor, secure the glass in the full up position with tape.
Item 12: Rear Door Window Glass Top Run Removal Note
1. Remove the glass top run through the top opening of rear door.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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 and removing the glass from the vehicle.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician
Safety Information > Page 10779
Windshield: Vehicle Damage Warnings
CAUTION:
- After installing the urethane installed glass, the vehicle should not be driven until the urethane has
cured. The curing time for temperatures above 13°C (55°F) and relative humidity above 50% is
12-24 hours. (Refer to Drive Away chart for cure times as temperature and humidity vary).
Inadequate curing of the urethane may adversely affect the strength of the urethane bond.
- If the vehicle is to be driven within 24 hours of urethane sealant application, urethane sealant
Essex U-216 meeting Ford Specification WSB-M2G316-B must be used due to it's one hour cure
time.
- Do not scratch pinch weld area.
- Open the windows to prevent the windshield glass from being pushed out by air pressure if doors
are closed.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
10780
Windshield: Service and Repair
WINDSHIELD GLASS
Special Tool(s)
SPECIAL TOOL(S)
WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses
and heavy gloves when cutting and removing the glass from the vehicle.
REMOVAL
1. Remove right and left side A-pillar trim panels, sun visors and retainers and if equipped
overhead console. 2. Remove the interior mirror. 3. Lower the front portion of the headliner. 4.
Remove the cowl panel grille.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
10781
5. Remove the components in the order indicated in the illustration and table.
Item 2: Windshield Glass Removal Note
1. NOTE:
- Lubricate the urethane adhesive with water to aid the special tool when cutting.
- Removing the windshield glass requires more than one technician.
- Be sure not to scratch the pinch weld while removing windshield glass.
Using the special tool, cut the urethane adhesive from the windshield glass starting at the top
center and working towards the bottom corners.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
10782
2. Using the special tool, distance the windshield from the body.
3. Using the special tool, cut the remaining urethane adhesive and remove the window glass. 4.
Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld. 5. Be sure
not to scratch the pinch weld when removing the windshield glass.
INSTALLATION
1. To install, reverse the removal procedure.
Item 2: Windshield Installation Note
1. CAUTION:
- After installing the urethane installed glass, the vehicle should not be driven until the urethane has
cured. The curing time for temperatures above 13°C (55°F) and relative humidity above 50% is
12-24 hours. (Refer to Drive Away chart for cure times as temperature and humidity vary).
Inadequate curing of the urethane may adversely affect the strength of the urethane bond.
- If the vehicle is to be driven within 24 hours of urethane sealant application, urethane sealant
Essex U-216 meeting Ford Specification WSB-M2G316-B must be used due to it's one hour cure
time.
- Do not scratch pinch weld area.
- Open the windows to prevent the windshield glass from being pushed out by air pressure if doors
are closed.
Dry fit the windshield. Make alignment marks with tape or non-staining pencil.
2. Trim the remaining urethane adhesive on the pinch weld to within specification. The surface
should be smooth and free of cuts and contamination. 3. Use the wool applicator to apply adhesive
meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to
ten
minutes to dry.
4. NOTE:
- If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page
10783
- Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic-coated
area is clean.
- Wipe off glass prep immediately after each application.
Apply glass prep meeting Ford specification WSB-M2G314-B twice around the glass surface.
5. Apply glass primer meeting Ford specification WSB-M5B280-C to the same area that was
prepped in the previous step. Allow five minutes to
dry.
6. Cut the urethane applicator tip to specification.
7. Apply a bead of urethane adhesive meeting Ford specification WSB-M2G316-B to the pinch
weld just outside the foam dam. 8. Install the windshield by aligning it to the marks previously
made. 9. After the windshield glass has set, check for water leaks and add urethane where
needed.
Item 1: Windshield Glass Moulding Assembly Installation Note
1. Install glass moulding prior to glass installation.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
View 151-15
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Fluid Level Switch > Component Information > Locations > Page 10789
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Fluid Level Switch > Component Information > Locations > Page 10790
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
View 151-25
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 10794
Windshield Washer Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 10795
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 10796
Windshield Washer Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 10797
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
View 151-25
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 10801
Wiper Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 10802
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 10803
Wiper Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 10804
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid > Component Information > Specifications >
Capacity Specifications
Washer Fluid: Capacity Specifications
Fill to the line on the reservoir.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid > Component Information > Specifications >
Capacity Specifications > Page 10809
Washer Fluid: Fluid Type Specifications
Windshield Washer Fluid Type .........................................................................................................
Motorcraft Ultra-Clear Windshield Washer Fluid
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
View 151-15
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Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 10813
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> Page 10814
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions > Technician Safety Information
Windshield Washer Pump: Technician Safety Information
WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all
cautions and warnings indicated on the label of the container. Failure to follow these instructions
could result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions > Technician Safety Information > Page 10822
Windshield Washer Pump: Vehicle Damage Warnings
CAUTION:
- When replacing the windshield washer pump be careful not to damage the rubber grommet.
- Do not operate the windshield washer pump before filling the reservoir. Failure to do so could
result in premature pump failure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions > Page 10823
Windshield Washer Pump: Service and Repair
WINDSHIELD WASHER PUMP AND RESERVOIR
WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all
cautions and warnings indicated on the label of the container. Failure to follow these instructions
could result in personal injury.
CAUTION:
- When replacing the windshield washer pump be careful not to damage the rubber grommet.
- Do not operate the windshield washer pump before filling the reservoir. Failure to do so could
result in premature pump failure.
NOTE:
- To prevent spilling windshield washer fluid, drain fluid from the windshield washer reservoir before
removal.
- The windshield washer reservoir is removed through the bottom of the engine compartment.
REMOVAL
1. Remove the air cleaner assembly. 2. Remove the RH front splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
Precautions > Page 10824
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
Precautions > Technician Safety Information
Windshield Washer Reservoir: Technician Safety Information
WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all
cautions and warnings indicated on the label of the container. Failure to follow these instructions
could result in personal injury.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
Precautions > Technician Safety Information > Page 10829
Windshield Washer Reservoir: Vehicle Damage Warnings
CAUTION:
- When replacing the windshield washer pump be careful not to damage the rubber grommet.
- Do not operate the windshield washer pump before filling the reservoir. Failure to do so could
result in premature pump failure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
Precautions > Page 10830
Windshield Washer Reservoir: Service and Repair
WINDSHIELD WASHER PUMP AND RESERVOIR
WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all
cautions and warnings indicated on the label of the container. Failure to follow these instructions
could result in personal injury.
CAUTION:
- When replacing the windshield washer pump be careful not to damage the rubber grommet.
- Do not operate the windshield washer pump before filling the reservoir. Failure to do so could
result in premature pump failure.
NOTE:
- To prevent spilling windshield washer fluid, drain fluid from the windshield washer reservoir before
removal.
- The windshield washer reservoir is removed through the bottom of the engine compartment.
REMOVAL
1. Remove the air cleaner assembly. 2. Remove the RH front splash shield.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
Precautions > Page 10831
3. Remove the components in the order indicated in the illustration and table. To remove individual
components, only carry out the listed steps.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
View 151-25
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> Page 10835
Windshield Washer Switch: Diagrams
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
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> Page 10836
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 10837
Windshield Washer Switch: Testing and Inspection
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 10838
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector
Views
Wiper Motor: Connector Views
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 10843
Wiper Motor: Service Precautions
CAUTION:
- Do not handle the windshield 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
windshield wiper motor inoperative. Rough handling of new windshield wiper motors may also
damage the motor magnets.
- Do not handle the rear window 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 rear
window wiper motor inoperative. Rough handling of new rear window wiper motors may also
damage the motor magnets.
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection >
Windshield Wiper Motor
Wiper Motor: Testing and Inspection Windshield Wiper Motor
WINDSHIELD WIPER MOTOR
CAUTION: Do not handle the windshield 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 windshield wiper motor inoperative. Rough handling of new windshield wiper motors may also
damage the motor magnets.
NOTE:
- Windshield wiper motor component test is carried out to determine if windshield wiper motor and
module are functional and not in software safe mode. Refer to Principles of Operation for software
safe mode parameters.
- Battery voltage must remain within 10 to 15 VDC to carry out test and keep windshield wiper
motor from entering its software safe mode.
- When connecting the power and ground test leads to the windshield wiper motor terminals, care
must be taken to not short terminals between power and ground, as well as making sure the logic
ground, pin 3, is always securely connected to prevent permanent windshield wiper motor module
damage.
If the windshield wiper motor does not pass any of the following tests, install a new windshield
wiper motor.
Use SABRE Premium Battery and Electrical System Tester to test the windshield wiper motor.
To test the windshield wiper motor, remove the windshield wiper mounting arm and pivot shaft from
the windshield wiper motor. Refer to Windshield Wiper Blade and Pivot Arm Adjustment.
Disconnect the wiper motor. Connect the (1) green lead from the (2) SABRE to the battery negative
(-) post. Connect the red lead (3) from the SABRE to the wiper motor (4) component side connector
ground and logic ground pins 6 and 3 (3). Connect battery positive cable (5) to windshield wiper
motor (4) component side connector battery and logic positive pins 5 and 8 (5).
Low Speed
Test the low speed mode by connecting a separate set of test leads from battery ground (-) post to
windshield wiper motor (4) component side pins 9 and 10 (6). When these pins are grounded, the
windshield wiper motor operation should now be in low speed mode.
High Speed
Test the high speed mode by connecting a separate set of test leads from battery ground (-) post to
windshield wiper motor (4) component side pins 1, 9, and 10 (7). When these pins are grounded,
the windshield wiper motor operation should now be in high speed mode.
Washer Pump Relay (Integral)
Test the windshield wiper motor internal washer relay function by measuring the voltage between
windshield wiper motor (4) component side pin 7 (8), and ground while grounding the windshield
wiper motor (4) component side pin 12 (9). When wash command input pin 12 is grounded,
measured
Ford Explorer Awd Workshop Manual (V6-4.0L VIN K Flex Fuel (2003))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection >
Windshield Wiper Motor > Page 10846
voltage should read 10 volts or greater.
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection >
Windshield Wiper Motor > Page 10847
Wiper Motor: Testing and Inspection Rear Window Wiper Motor
REAR WINDOW WIPER MOTOR
CAUTION: Do not handle the rear window 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 rear window wiper motor inoperative. Rough handling of new rear window wiper motors may
also damage the motor magnets.
NOTE:
- Rear window wiper motor component test is carried out to determine if wiper motor and module
are functional and not in software safe mode. Refer to Principles of Operation for software safe
mode parameters.
- Battery voltage must remain within 10 to 15 VDC to carry out test and keep wiper motor from
entering its software safe mode.
- When connecting the power and ground test leads to the rear wiper motor terminals, care must be
taken to not short terminals between power and ground, as well as making sure the logic ground,
pin 3, is always securely connected to prevent permanent rear window wiper motor module
damage.
If the rear window wiper motor does not pass any of the following tests, install a new rear window
wiper motor.
Use the SABRE Premium Battery and Electrical System Tester to test the rear window wiper
motor.
Disconnect the rear window wiper motor. Connect the (1) green lead from the (2) SABRE to the
battery negative (-) post. Connect the red lead (3) from the SABRE to the wiper motor (4)
component side connector ground pins 1 an 2 (3). Connect battery positive cable (5) to wiper motor
(4) component side connector battery and logic positive pins 3 and 4 (5).
On Mode
Test the on mode by connecting a separate set of test leads from battery ground (-) post to
windshield wiper motor (4) component side pins 6 and 7 (6). When these pins are grounded, the
rear window wiper motor operation should now be in on mode.
Washer Pump Relay (Integral)
Test the rear window wiper motor internal washer relay function by measuring the voltage between
wiper motor (4) component side pin 5 (7), and ground. When wash command input pin 6 (7) is
grounded, measured voltage should read 10 volts or greater.
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Wiper Switch: Diagrams
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10852
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Wiper Switch: Testing and Inspection